®DEUTZLIVEThe magazine of DEUTZ AG Edition 1/2010

New drive – Curtain up for the technology of the future

TechnologyNew names for new technology

ExpertiseHow DEUTZ found a way out of the crisis

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Editorial

New drive

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Dr Helmut Leube

The 2009 financial year has been one of the most difficult in DEUTZ AG‘s long history. For the first six months of 2008, impressive

results were still being reported. Then two years ago this summer an unforeseeable crisis began to set in that went beyond the financial sector and soon entered the real economy. For DEUTZ this meant having to cope with severe setbacks. What began as a consequence of poor specula-tion by bankers, soon entered the real econo-mies of North America and Europe and resulted in a dramatic drop in demand, primarily for mo-bile machinery, our largest segment. Engine unit sales more than halved going from 252,359 units down to 117,961 units with the drop in revenue being slightly less at 42.2 % and amounting to g863.4 million. Operating profit before one-off items crashed to g–46.3 million. But in this dif-ficult year we quickly took appropriate measures. Since its start, the MOVE package of measures to reduce costs and raise efficiency, has achieved savings of around g136 million from material and

overhead costs. However, personnel measures, such as short-time working, temporary staff cut-backs, early retirement and even enforced redun-dancies, were still necessary to achieve long-term reductions in fixed costs and to ensure our com-petitiveness. In addition, over the past 12 months we have sharply focussed on our working capital and cash flow situations. Internal financing has meant a positive operative cash flow situation de-spite the severe collapse in sales. By the end of 2009, we had managed to survive the crisis prac-tically debt-free.

For the first time since the onset of the crisis, we were able to report a clear rise in demand at the year end. The fourth quarter confirmed the trend with an approximate positive operating result. DEUTZ has passed the low point of the crisis. Looking to this year, we can affirm a clear con-tinuation of this positive development. Turnover and sales for the first quarter of 2010 are above expectations. A significantly improved order book means we can expect 2010 to be much better than 2009.

Find out on p.18 how DEUTZ set a new course for the future while being in the midst of the big-gest crisis of current times. In spite of the severe economic situation we kept looking ahead and developed the two new TCD 2.9 L4 and TCD 3.6 L4 engines. They are also the central point of this year‘s bauma stand (p.8). And it isn‘t just these two that are new at DEUTZ. To highlight the tech-nological advance represented by the develop-ment of our engines for Tier 4 interim emissions, all DEUTZ engines from this emission stage will receive new product designations. Find out on p.10 how these will look.

Dear DEUTZ LIVE readers, we have shown that even in times of crisis we do not lose sight of what‘s important. Technological expertise and the ability to demonstrate strength under extreme conditions is what marks us out. Looking to the future – that is DEUTZ. Let us look ahead together and go into the future with new energy from our new engines.

Yours,

Dr Helmut Leube

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4 DEUTZLIVE 01/2010

Contents

10 With the introduction of engines for the stricter EU emissions stage IIIB/US EPA Tier 4 interim, DEUTZ is changing its range of model designations

Title photo DEUTZ presents

the new 4-cylinder TCD 2.9 L4 engine

Title

8 New drive - Curtain up for the technology of the future In the midst of the crisis DEUTZ sets a future

course and develops two new engines

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10 New names for new technology New product designations provide DEUTZ

customers with important product information

13 Top theme: Exhaust gas aftertreatment DEUTZ symposium on exhaust gas aftertreatment

at bauma 2010

14 Restrained power The power of a DEUTZ engine in the Bomag

“hybrid roller”

16 Super with DEUTZ The new fl agship from Joseph Vögele AG:

The Super 3000-2 - powered by DEUTZ

18 How DEUTZ found a way out of the crisis Following record results for 2007, the crisis then hit

DEUTZ. But the long-established company managed to

reverse the trend

20 Weightless with DEUTZ DEUTZ provides transport at the

Leipzig/Halle Airport

22 DEUTZ at the top of world In the world’s highest country DEUTZ

provides dependable energy supplies

Topics

3 Editorial

6 News

23 Press news

23 Reader activity

Contents

IMPRINT | DEUTZ LIVE Edition 1/2010 | PUBLISHED BY DEUTZ AG, Ottostraße 1, 51149 Köln (Porz-Eil) | RESPONSIBLE Janina Decker, Company Communication |

OBJECT MANAGEMENT Janina Decker, Phone: +49 (0)221 822 24 93, Fax: +49 (0)221 822 15 24 93, Email: decker.j@deutz.com | EDITORS Janina Decker | DESIGN department Agentur für

Kommunikation, Köln | CREATIVE DIRECTOR Yusuf Öztürk | LAYOUT Michael Göken, Nina Kanani | PHOTOS/ILLUSTRATIONS Janina Decker, DEUTZ AG, Shutterstock, Fotolia, Pixelio, Leipziger

Flughafen, Bomag, Vögele | PRINTED BY Druckpartner, Essen

14 Powered by DEUTZ - the Bomag “hybrid roller”

20 Weightless with DEUTZ - DEUTZ in action at the Leipzig/Halle Airport

22 Extreme conditions: Since 2009 DEUTZ has had a presence in the Nepalese market

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6 DEUTZLIVE 01/2010

News

Las Vegas

Strong showing

Cologne

JIS centre opens

Ulm

500,000 DEUTZ engines from Ulm

DEUTZ AG demonstrates forward-looking at the World of Concrete in Las Vegas. From 2 - 5 February 2010, DEUTZ was at one of the USA’s most prestigious con-struction trade fairs presenting its machin-ery engines that meet the stricter US EPA Tier 3/ Tier 4 interim emission standards. A wide range of exhaust gas aftertreatment components from the DVERT® system also awaited trade fair visitors. DEUTZ present-ed DVERT® components, filters and SCR technology as display models as well as exhibiting the TCD 2010, TCD 2011, TCD 2012 engine series. A special highlight for visitors was a computer-aided simu-lation of the brand new engine with the preliminary project designation TCD 20XX.

DEUTZ again demonstrates it is in the forefront of engine manufacture optimisation by investing €2.5 million in a new just-in-sequence (JIS) assembly centre at its Porz location in Cologne. Within a 12,000 m² building, DEUTZ is optimising its assembly processes and material management to deal with the increasing product diversity resulting from new emissions legislation. The wide variety of individual compo-nents are picked just-in-time in the required sequence. In many cases they are then pre-assembled before being delivered to the assembly lines. Suppliers send components to the JIS centre on just the day required enabling a permanent reduction in on-site stock levels. To manage the material, the components are made available in the form of sequence boxes at more than 30 workstations. The switch to delivery via the JIS centre already began in mid-2009. Production management systems were switched to full sequencing with different orders being lined up at assembly like a string of pearls. With the required lead times, the JIS centre and suppliers can then deliver just the right level of materials at just the right time. With the implementation of JIT (Just in Time) / JIS (Just in Sequence) logistics, DEUTZ is optimising its workflows within engine production. In future, only those basic components used on all engine variants will be held at the assembly line workstations with sequencing doing away with the need for walkways. Around 50 staff, who formerly worked within assembly, are to be em-ployed in the JIS centre on a two-shift basis. In their new roles they will sequence supply up to 50 separate engine assembly workstations.

A milestone has been reached at the DEUTZ plant in Ulm. At the turn of the year, the 500,000st DEUTZ engine rolled off the production line at the Ulm-Donautal site. The Ulm site went into production in 1967. The team there is then able to draw on decades of experience in the design and assembly of air-cooled and water-cooled engines. It all began with production of the air-cooled FL312 V-engine, with the FL413 engine series being added just one year later, a series that is still enjoying success today as part of the product range. In 1993 production commenced in Ulm of the 1015 water-cooled en-gine series To date over 35,000 units of this engine type have left the site in a multitude of variants. It became popular through its use in the Dakar Rally, the world‘s toughest off-road motor race, with its proven reliability and robustness helping many race teams to success. The V-engines of the 413/513 and 1015/2015 production series deliver im-pressive performance and efficiency whether on road in heavy goods vehicles, on construction sites, in mines or on rails. They have made Ulm the centre for air and water cooled engines with a displacement over 8 litres. Ulm is also the centre for all DEUTZ‘s marine activity. The relocation of production of the 912/913/914 air-cooled engine series from Cologne to Ulm in late 2006/early 2007 marked the most important turning point in the plant‘s recent history. The Ulm plant to-day produces air-cooled and water-cooled engines with a power output of up to 500kW for use in stationary equipment, construction equip-ment, commercial vehicles and rail vehicles.

DEUTZ at the WOC 2010

The 500,000st DEUTZ engine from Ulm

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News

Cologne

Bosch, DEUTZ and Eberspächer set up joint venture for diesel exhaust aftertreatment

Cologne

Friends Association established for DEUTZ AG engine collection

Cologne

Volvo and DEUTZ sign new supply agreement

On 9 December 2009, Robert Bosch GmbH, DEUTZ AG and Eberspächer GmbH & Co. KG signed an agreement to set up a joint venture in diesel aftertreatment. On 7 April 2010, the “Bosch Emission Systems” joint venture was approved by the EU Commission and may now begin operations. Bosch Emission Systems, based in Stutt-gart, is to utilize the core competencies in exhaust gas aftertreatment from the three participating companies, and to offer complete modularised system so-lutions for construction and agricultural machinery as well as for commercial ve-hicles. This includes electronic control-ling and, if required, burner technology for the regeneration of diesel particulate

filters. The products on offer are tailored to mobile machinery such as excavators, wheel loaders, tractors and combine har-vesters, as well as to stationary systems. Other areas of usage are commercial ve-hicles such as heavy goods vehicles and buses. The concept is based on a modularised system. A large pool of standard compo-nents enables custom-built exhaust gas aftertreatment systems to be assembled for any vehicle or any machine. “We have made a name for ourselves as an engine manufacturer who can provide individual solutions for our customers. We are now bringing this important know-how to the joint venture and by doing so we are not only investing in our own products, but

In cooperation with the Cologne City Museum, DEUTZ AG has established a Friends Association for the preservation and upkeep of its historical engine collec-tion. The aim of the „Friends of DEUTZ‘s Engine Collection“ is to safeguard and maintain DEUTZ‘s unique engine collec-tion, a collection that is also protected through its registration as a German national cultural asset. This unique and historical collection goes back to the year 1875. Already in 1925, exhibits could

be viewed by the public in a company museum. The association encourages broad public access to the collection, e.g. through visitor schemes as well as the financing of new exhibits and restoration projects.

Helmut Müller, who heads the history ac-tivities for DEUTZ, holds the chairmanship of the Friends Association. Its deputy is Dr. Michael Euler-Schmidt, acting Director of the Cologne City Museum.

The Volvo Group has been working close-ly for many years with the DEUTZ engine manufacturer. In 1998 both companies signed an agreement for the development and supply of diesel engines with displace-ments from 4-7 litres. The agreement was made for a 15 year period and comes to an end in 2013.The new supply agreement will come into effect from 1 January 2014. It covers the further development of medium-sized DEUTZ industrial engines for the Europe-an COM IV and US Tier 4 final emission standards. The agreement means DEUTZ remains the sole supplier of 4-8 litre en-gines for Volvo’s construction machinery.

DEUTZ will also continue to supply engines complying with the Euro 3, 4 and 5 emis-sions standards for existing use in Volvo commercial vehicles. “We pride ourselves on the success of the collaboration and look forward to it continuing over the long term.” says Dr. Helmut Leube, CEO of DEUTZ AG.

NOTICES | In brief

Management team for DEUTZ Dalian now complete

Since August 2007 DEUTZ AG and FAW Jie-fang Automotive Co. Ltd. (FAW), a wholly owned subsidiary of China First Automo-bile Works Group Corp. (FAW Group) in Da-lian, China, have been supporting the joint venture DEUTZ (Dalian) Engine Co., Ltd. (DDE). The Cologne engine manufacturer is responsible for the joint venture’s industrial management and last year introduced new personnel to pivotal managerial positions in order to hasten the young venture towards profit-making.The 41 year old Bernd Hoffmann has be-come the Chinese company’s new CEO. The mechanical engineer had previously spent five years as head of the CLAAS Hungaria Kft. in Hungary. He has also headed produc-tion systems at CLAAS KGaA in Harsewinkel in Germany.With Stella Teng as the new CFO, the DEUTZ Dalian Diesel Engine Ltd. management team is now complete. The 53-year-old has worked for, among others, the Pfizer company in China. Teng, who has an MBA from the Uni-versity of Michigan, last held the CFO posi-tion at DHL-Sinotrans in China. With the joint venture located in the north Chinese city of Dalian, DEUTZ is significantly expanding its presence across the Chinese market. DEUTZ Dalian manufactures and sells diesel engines for commercial vehicle as well as industrial applications. For the 2009 financial year, the joint venture manu-factured approximately 99,500 engines of which around 6,700 were 4 to 8 litre engines built on the basis of licensed DEUTZ tech-nology.

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also in the fast-growing market for exhaust gas af-tertreatment systems”, stated Gino Mario Biondi, the Management Board Member for technology at DEUTZ AG. By using practically only standardized components means significant competitive advan-tages in respect of cost, development time and va-lidation time. Modular systems also give flexibility. Individually designed tubing solutions enable opti-mal utilization of the restricted installation space on mobile machinery.Series production of the aftertreatment units for diesel engines is planned to begin in the third quar-ter of the current year. Around 100 staff from the participating companies will be employed by Bosch Emission Systems with 20 of these coming from DEUTZ AG.

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8 DEUTZLIVE 01/2010

Title

New drive – Curtain up for the technology of the future

DEUTZ demonstrates that it is forward-looking by

presenting at bauma 2010 two new engines,

the TCD 2.9 L4 and TCD 3.6 L4.

Their distinguishing features are a compact design, high performance and proven reliability. The TCD 2.9 L4 is the new engine from DEUTZ. DEUTZ is presenting the new engine for the fi rst time at bauma 2010. It had been announced with the preliminary project designation TCD 20XX.

Available in both naturally aspirated and turbocharged versions (with or without a charge air intercooler) and equipped with cooled external exhaust gas recirculation and 1,600 bar common rail high-pressure

injection, the ultracompact 4-cylinder 2.9 litre-series in-line engine covers a performance range from 25 to 56 kW. The compact engine, specially developed for extremely short and space-restricted installa-tions, offers high performance and torque with very smooth running. The engine achieves a maximum 300 Nm of torque at 1,600 rpm.

A modular exhaust gas aftertreatment system has been designed to meet the industrial machinery need for compactness and cost effi ci-ency. A maintenance-free and cost-effective diesel oxidation catalytic converter (DOC), along with a particle oxidation catalytic converter (DOC + POC), can cater for most applications. A closed DPF option (diesel particle fi lter) is also available. For the TCD 2.9 L4 there is also a complete range of customer op-tions including effi cient lateral auxiliary drives and mass compensati-on shafts. Oil change intervals at 500 h and a maintenance-free valve train increase productivity and lower operating costs. Low noise levels

technology of the future

TCD 2.9 L4

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Title

TCD 3.6 L4TCD 3.6 L4

give further cost savings by reducing insulation requirements.The TCD 2.9 L4 gets its fi rst offi cial public showing at the DEUTZ AG stand at bauma. The new engine had an initial showing at the Agritech-nica in Hanover in November 2009, albeit as a virtual presentation. A computer assisted animation enabled trade fair visitors to get a preli-minary glimpse of the DEUTZ technology of tomorrow.

The TCD 2.9 L4 is however not the only new engine from DEUTZ. Whilst in the middle of the most extreme economic situation of recent deca-des, DEUTZ consciously invested in the future by developing the new TCD 3.6 L4 engine.

The water cooled TCD 3.6 L4 has a power range of 50 to 85 kW and achieves a maximum of 400 Nm of torque at 1,400 - 1,600 rpm. The turbocharged 4-cylinder engine, available with or without a charge air intercooler and cooled external exhaust gas recirculation, is equipped

with a 1,600 bar common rail system and impresses through its low power to weight ratio and high power density. Long service intervals also help to keep maintenance costs down. The TCD 3.6 L4, like all DEUTZ engines, has extremely good cold-start properties and is there-fore suited for use in extreme climatic conditions. A particle oxidation catalytic converter (DOC + POC) is available for exhaust gas after-treat-ment, as well as having a DPF (diesel particle fi ltered) option.

With the introduction of new emission standards, the two newly de-veloped TCD 2.9 L4 and TCD 3.6 L4 engines tie in with the legendary DEUTZ 2011-series, which remains in production for current emissi-on standards. “DEUTZ stands for innovations and best-in-class tech-nology. Our new engines combine maximum customer benefi t with minimum operating costs. This will extend and further strengthen our technological leadership,” emphasized Gino Mario Biondi, DEUTZ Managing Director of Development and Production. $P

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New names for new technologyThere are other signs of change at DEUTZ as well as the new TCD 2.9 L4 engine

being presented at bauma 2010.

DEUTZ is at the world’s largest trade fair for construction and min-ing machinery as a leading tech-nological provider of low-emission diesel engines with a broad perfor-mance range of 25-520 kW. With the introduction of engines for the stricter EU emissions stage IIIB/US EPA Tier 4 interim, DEUTZ is altering its entire range of model designa-tions to highlight this technological advance.

Self-explanatory and succinct en-gine designation codes will provide customers with all the required product information. The first three letters give specifics such as turbo-charger, intercooling and fuel type. This is followed by engine displace-ment in litres as well as cylinder set up and number. Engines still being produced according to current and earlier emissions standards are to retain their existing designations.

At just a glance, the new desig-nation codes therefore provide a unique aid to DEUTZ customers.

In the mid-range performance seg-ment, DEUTZ has extensively devel-oped its tried and tested 2012-se-ries in-line engines for the next emissions stage. In the 70 to 115 kW performance range, DEUTZ can offer customers the water-cooled TCD 4.1 L4 engine, which deliv-ers a maximum torque of 610 Nm at 1,400 to 1,600 rpm. The tur-bocharged, intercooled 4-cylinder in-line engine is equipped with a 1,600 bar DEUTZ common rail sys-tem (DCR®) and cooled external ex-

Innovation

10 DEUTZLIVE 01/2010

Previousengine designation

TCD 20XX L04

TCD 2010 L04

TCD 2012 L04

TCD 2012 L06

TCD 2013 L06

TCD 2015 V06

TCD 2015 V08

Newengine designation

TCD 2.9 L4

TCD 3.6 L4

TCD 4.1 L4

TCD 6.1 L6

TCD 7.8 L6

TCD 12.0 V6

TCD 16.0 V8

Number of cylinders

L: In-line engineV: V-engine

Displacement in litres (rounded)

Diesel engine

Turbocharged engine

Intercooled

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haust gas recirculation. The robust engine design impresses through its high power density, outstanding reliability and long service intervals. A range of customised options are available for the 4-cylinder engines including effi cient lateral auxiliary drives and mass compensation shafts. The modular exhaust gas aftertreatment system provides a closed diesel particle fi lter (DPF) whose regeneration is aided by a controlled aircore choke.

In the 120 to 180 kW performance range, DEUTZ offers the water-cooled TCD 6.1 L6 with a maximum torque of 1,000 Nm at 1,400 to 1,600 rpm. The robust 6-cylinder in-line engine is equipped with a tur-bocharger and intercooler, cooled external exhaust gas recirculation and an electronically controlled DEUTZ 1,600 bar common rail system (DCR®) with high-pressure injection for power ranges up to 160 kW and 2,000 bar for top-of-the-range performance. The engine impresses through its outstanding cost effectiveness, long engine ser-vice life and long service intervals. A closed diesel particle fi lter (DPF) with aircore choke regeneration for

Innovation

INFO | Displacement

Displacement is one clear indicator of an engine’s classifi cation. It is the sum of all the cylinders’ combustion chambers. For each cylinder, the combustion chamber is calculated from the amount of travel availa-ble to the piston (stroke) and the cylinder diameter (bore), using the formula bore (cm3) x stroke (cm). Power = torque x rpm

power ranges less than 130 kW, and diesel burner regeneration for power ranges greater than 130 kW, enables the TCD 6.1 L6 to fulfi l the requirements of the new emission levels.

The water-cooled 6-cylinder TCD 7.8 L6 engine, with performance ranges of 160 to 250 kW, is the most powerful engine in the mid-range power class. It achieves a maximum torque of 1,400 Nm at 1,400 to 1,600 rpm. The engine has a turbocharger with a charge air intercooler, cooled external exhaust gas recirculation, wet cylinder liners and a DEUTZ 2,000 bar common rail (DCR®) high-pressure injection sys-tem, and is designed for heavy-duty operation. The high-performance engine has excellent power den-sity and outstanding reliability with long service intervals. The TCD 7.8 uses an exhaust gas aftertreatment system to meet the heavy-duty re-quirements of industrial machinery. A closed diesel particle fi lter (DPF) with active diesel burner regen-eration ensures maximum machine availability under any conditions.

The TCD 12.0 V6 covers the 240 to

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12 DEUTZLIVE 01/2010

390 kW performance range. The V-confi guration water-cooled engine is turbocharged and intercooled, and is equipped with wet cylinder liners and common rail high-pressure injection with an injection pressure of 2,000 bar. The compact V-design en-ables it to be used within extremely small installation dimen-sions. Designed for heavy-duty use, the TCD 12.0 impresses through its robustness and long maintenance intervals. With its proven high-performance SCR technology, the TCD 12.0 is de-signed for the needs of large, heavy-duty industrial machinery for which fuel consumption is a major priority.

The high-end engine is the powerful TCD 16.0 V8. The water-cooled 350 to 520 kW 8-cylinder engine rounds off the DEUTZ range of products for the IIIB / Tier 4 interim emissions stan-dards. Equipped with a turbocharger, charge air intercooler and wet cylinder liners, the TCD 16.0 generates a maximum torque of 2,890 Nm at 1,400 rpm, and impresses through optimal per-formance characteristics. A modern 2,000 bar electronic com-mon rail injection system combined with an SCR exhaust gas after-treatment system achieves reductions in environmentally harmful emissions. The compact V-engine design requires sig-nifi cantly less space and therefore reduces installation costs for customers. $

TCD 2.9 L4 TCD 16.0 V8TCD 3.6 L4 TCD 6.1 L6TCD 4.1 L4 TCD 12.0 V6TCD 7.8 L6

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Top theme: Exhaust gas aftertreatmentDEUTZ symposium on exhaust gas aftertreatment

at bauma 2010

Because this year’s bauma fo-cuses on the range of applica-tions for construction machinery and vehicles, then exhaust gas aftertreatment will also take on a central role. From January 2011 and commencing with per-formance classes from 130kW to under 560kW, diesel engines for mobile machinery must com-ply with EU exhaust gas stage IIIB and US EPA Tier 4 interim. These require a clear reduction in particle and NOx emissions For DEUTZ this means not only complying with the differing global emissions legislation but

also meeting customer require-ments as effectively and as eco-nomically as possible as well as providing them individually with their power-drive needs. DEUTZ is well prepared for emissions reductions and demonstrates its expertise again at this year’s bauma. The challenges and inno-vative technologies arising from the new emissions legislation are to be presented by DEUTZ on 21 April 2010 at a “DEUTZ mod-ular technologies for new emis-sion standards” symposium. Numerous experts will be avail-able to answer questions on ex-

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haust gas aftertreatment and to provide information on the new exhaust levels, the DVERT® sys-tem (DEUTZ Variable Emission Reductions Technology) as well as the newly designed TCD 2.9 L4 engine. $

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Expertise

14 DEUTZLIVE 01/2010

Restrained power

The Bomag “hybrid roller”:

power from DEUTZ

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Expertise

15

Customers from the construction machinery

branch require above all that the power units

of their equipment can cope with the highest

of demands and can demonstrate above aver-

age capability and reliability. In addition, the

power units must be energy-efficient, low on

fuel consumption and environmentally friendly

by complying with the stricter emissions regu-

lations. Too much to ask? Not for DEUTZ. At

bauma 2010, Bomag presents a roller proto-

type whose DEUTZ hybrid drive meets every

one of these requirements.

Global demands for CO2 reduc-tions are leading to an increas-ingly growing discussion on al-ternative power drive designs. Hybrids in the passenger vehicle segment have been around for years but remain the exception for mobile machinery. Already in 2007 DEUTZ was pioneer-ing the development of a hybrid drive for a wheel loader for the Atlas Weyhausen company. This was a sensation for non-road applications. The AR 60 wheel loader has meanwhile found a successor that is on the way to being series-produced with the DEUTZ hybrid drive (DEUTZ LIVE reports).

The DEUTZ hybrid drive is also highly suited to other construc-tion machinery. The compacting of asphalt is ideal for utilizing hybrid technology. Compacting is characterised by a roller’s nonstop reversing manoeuvres: braking, direction change and then a short burst of accelera-tion. On top of this, the com-pacting process requires an on and off activation of a generator system, which requires still more power.

DEUTZ again takes a pioneering role in collaboration with its part-ners. At bauma 2010, Bomag, the global leader in compacting technology as well as a manu-facturer for earth, asphalt and waste compacting equipment, presents its original field tested “hybrid roller” based on BW 174 AP AM, the most successful Bomag roller with a market share of more than 50 percent.

This “hybrid roller” uses a 47 kW TD2009 DEUTZ combustion engine and a DEUTZ hybrid sys-tem made up of an e-machine, a high-performance battery, along with powerful electronics and a maximum usable 22kW of elec-tric power. The hybrid system’s e-machine is integrated into the combustion engine’s flywheel housing thereby saving space.

The electronics and battery are easily accessible by being locat-ed in the roller’s door.

The operating principles of the DEUTZ hybrid system are both simple and efficient. The elec-tric motor takes energy from the battery and assists the main power unit as required, e.g. when switching to vibration or during acceleration. This then covers the peaks of when perfor-mance is needed. The concept enables a significantly reduced nominal performance level from the diesel engine, i.e. downsiz-ing, meaning no need for com-plex exhaust gas aftertreatment systems. During low engine-load phases, e.g. during braking or vibration system deactivation, the e-machine functions as a generator and recharges the bat-tery. Mechanical kinetic energy can then be recuperated. During optimal work phases the diesel engine always operates at its most efficient. A further feature of the system is its automatic start/stop function. When run-ning idle, and when consumers are shut down, the diesel en-gine automatically switches off. Movement of the drive lever, or the activation of a consumer, switches on the diesel engine via the e-machine. This takes place without any delay so that the operator can begin work im-mediately.This significantly reduces overall fuel consumption and the asso-ciated emissions of CO2. Initial tests have been very promising with diesel savings of up to thirty percent.

The tested prototype can be seen at bauma 2010. Advanced compacting engineering coupled with frontline engine technology - making the BW174 AP hybrid into a 21st century roller. $

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16 DEUTZLIVE 01/2010

Expertise

The new construction or resurfacing of motorways, major or minor roads and airports cannot happen without pavers. Vögele offers crawler equipped road-pavers in power classes for any use. What they all have in common is economy combined with reliability. The newly developed SUPER 3000-2 is the new leader in large pavers in performance capacity, techno-logical leadership and ergonomic comfort. With a lay down rate of up to 1,600 t/h and a pave width of up to 16 m, the paver can quickly lay down seam-less and very wide asphalt surfaces as well as completing major construction projects. The main requirements from a paver are reliability and the

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Expertise

ability to cope with heavy-duty stresses. Vögele therefore relies on the powerful drive technol-ogy from DEUTZ. The paver is equipped with the highly modern DEUTZ 6-cylinder TCD 2015 V06 4V diesel engine. This compact and powerful engine achieves a maximum power of 300 kW at 1,800 rpm. The TCD 2015 is equipped with an electronic, magnetic valve injection system that provides low fuel consumption and high economy. Compared to other large pavers of this class, consumption is low at around 217 g/kWh. The 6-cylinder engine naturally complies with the current EU-COM 3a and US EPA Tier 3 emission regulations.

The SUPER 3000-2 can also be operated in an “ECO-Mode” of 292 kW at 1,500 rpm thereby further reducing the paver’s already low fuel con-sumption and noise levels. The 2015 engine’s compact dimensions reduce the amount of installation space required and therefore also installation costs. $

bauma is the trade fair for new products and innovations for the construction

machinery sector. It then goes without saying that the DEUTZ name is constantly

referred to there. Just in time for bauma 2010, Joseph Vögele AG presents its

new flagship, the Super 3000-2 road-paver that leads the world’s largest paver

fleet. And what drives it? DEUTZ, of course.

Super with DEUTZ

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18 DEUTZLIVE 01/2010

Expertise

Just short of 286,000 engine sales was the record result for DEUTZ in the 2007 fi nancial year. The forecast

for 2008 was promising – engine sales were to reach the 300,000 level. Metaphorically speaking, the engines

were revving at levels never experienced before. The DEUTZ Board of Management and staff looked promisingly

to 2008 and expected another successful year.

The fi rst six months of 2008 seemed to fulfi l all expectations for DEUTZ, and the previous year’s success look as if it was to con-tinue. But then in September 2008, a report from the USA hit the headlines: the US Investment Bank Lehman Brothers appeared to be bankrupt. The reason was the bursting of a property bubble. Since the end of the 1990s, increasing numbers of Americans had got into debt in order to fulfi l their dreams of house ownership. The US property market boomed and houses purchased on credit continually rose in price enabling lending banks to give out even more credit. To fi nance the increasing levels of credit, banks began to trade the outstanding loans and offered them to the stock markets as securi-ties with guarantees of high returns. The US economy began to falter, the Federal Reserve Bank raised base rates and this led to lending banks then raising their interest rates on loans. This had the conse-quence of many house owners being unable to repay loans and then losing their homes. The securities, which were based on the property bubble, dramati-cally lost value with many banks having to resort to fi nancing the

losses through short-term and low interest loans to other banks. An increasing lack of confi dence then led to banks refusing to give each other credit. On 15 September, stock markets around the world collapsed with the German share index dropping to its lowest level since October 2006.

The crisis then extended beyond the fi nancial sector to the real economy with a force that nobody had predicted. What began as a property crisis then slowly hit DEUTZ. For the third quarter of 2008, DEUTZ reported a weakening in levels of incoming orders and sales, particularly for engines of less than four litres. It was soon clear that this was not a short term fi nancial crisis but a fundamental and long term shift in the global economy. The outlook for 2008 had to be adjusted to the new economic situation and the fi rst measures had to be implemented.

DEUTZ took a decision in October 2008 to commence the “MOVE” package of measures. The package contained short term measures

How DEUTZ found a way out of the crisis

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19

Expertise

intended to secure short term earnings as well as structural measures for long term improve-ments in performance. The pack-age’s cornerstones included a new pricing policy, increased productivity and efficiency tar-gets for manufacturing, R&D and quality control as well as a low-ering of material and overhead costs.

Staff levels also required adjust-ing to the drop in demand. In the second half of 2008, DEUTZ was compelled to implement an initial course of staff restructur-ing that continued into 2009 and eventually led to a reduction of more than 700 personnel. The Board of Management and em-ployee representative boards also agreed on short time work-ing, first for production and then for all company departments excluding R&D. These measures were also to continue through to the spring of 2010.

For the first half of 2009, DEUTZ had to report drastic downturns on incoming orders, sales and turnover. With the background of an ongoing global recession, overall sales and turnover had halved compared to 2008. The collapse of sales in the US meant up to 60 % losses in the under 4 litre engine segment. These heavy downturns pushed DEUTZ ever deeper into a trough whose way out was unknown. Despite all the uncertainties in making any prognoses, DEUTZ focused on maintaining and ex-panding its technological lead and continued to heavily invest in research and development in order to create a solid basis for future growth.

Staying power and technological expertise

While more than 85 % of staff in Germany went on to short-time working, in the development departments work continued at full speed on the new emission standards EU Stage IIIB/ US EPA Tier 4 interim and EU Stage IV /US EPA Tier 4, which are to come into force from 2011 to 2015 in western Europe and North America. At the Paris In-

termat trade fair in the spring of 2009, DEUTZ was able to present at one of the world’s most prestigious construction machinery trade fairs, its en-tire range of four litre products that comply with the new emis-sion standards. The engines received an excellent response and acceptance from the DEUTZ customers.

A further step included or-ganisational restructuring of the company. After the Board of Management was reduced from four to three members in

March 2009, there was then a significant slimming down by 35 percent of staff below manage-ment board level. Operational functions at the Cologne and Ulm locations were amalgamat-ed to achieve greater structural efficiency with faster decision-making procedures and a flatter hierarchy.

In the midst of the crisis DEUTZ then took another step towards the future. Together with Robert Bosch GmbH and J. Eberspächer GmbH & Co. KG, DEUTZ signed a “Memorandum of Understand-ing” on collaborating on the development, manufacture and marketing of diesel exhaust gas aftertreatment systems for the

non-road sector.

At the time of signing in the au-tumn of 2009, there appeared to be a slight stabilisation tak-ing place for the first time for over a year. Although this stabi-lisation was still at a low level, the trend, having already been evident in the second quarter, was confirmed by there being demand for DEUTZ engines and services in the third quarter of 2009 despite the ongoing dif-ficult economic situation. In September 2009, DEUTZ was able to achieve a satisfactory

performance for the first time in months, mainly through the progress made from the “MOVE” package of measures.

DEUTZ reaches a trend reversal

Despite all its cost-saving mea-sures, DEUTZ kept investing heavily in research and develop-ment. This enabled the new TCD 2.9 L4 and TCD 3.6 L4 engines to be virtually presented to the public at the Agritechnica 2009. They are examples of DEUTZ’s technological lead that it wants to expand on into the future.

The future began in the spring of 2010. In March of this year

DEUTZ could report that it had survived the crisis practically debt-free. This was made pos-sible not only from the €136m savings from “MOVE” but also a systematic management of working capital. The financial crisis has still hit DEUTZ hard. Turnover dropped by more than 42 % to around €863m and en-gine unit sales of 118,000 were not even half the level of the pre-vious year. But the worst seems to be over. The hard hit engine segment for construction ma-chinery has clearly recovered with orders currently exceeding

expectations. Short-time work-ing could also be lifted across the entire company. The outlook for 2010 is for a significant rise in sales and turnover.

In hindsight all these factors make one thing clear: A crisis is always a challenge. It demands being able to think differently, to be resilient and to know your strengths. Above all to be active and not reactive. Over the past year DEUTZ did not just react but acted by investing in future technology despite being in the midst of a recession. During the crisis, DEUTZ set a course for profitable growth and now goes strongly into the future reener-gized by its new engines. $

DEUTZ at the Intermat 2009 - sets future course during the crisis

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20 DEUTZLIVE 01/2010

Technology

Weightless with DEUTZThe Leipzig/Halle Airport is, at eighty years of operation, not only one of Germany’s most established airports but since 1990 has gradually expanded to become one of Europe’s most modern. It has a well-functioning and modern infrastructure and is an ideal travel hub, being locat-ed in the centre of Europe. Pas-senger aircraft are dispatched on the two 3,600 m runways and air freight comes and goes on a 24-hour basis. What appears to be practically weightless gener-ally isn’t, with the devil being in the detail.At a height of tens of thousands of metres, aircraft seem to move effortlessly through the clouds. But on the ground they need the sturdy help of aircraft tugs to move safely between take-off and park positions. The Gold-hofer AST 2R 210 is one such aircraft tug. Five of this type are being used at the Leipzig/Halle Airport, and there are a total of nine from Goldhofer that use DEUTZ engines. The AST 2R210

is multi-talented among towbar-less aircraft tugs. For the fast, reliable and safe ground trans-port of 100-300 ton aircraft, these tugs set real benchmarks thanks to their powerful engines. They enable Airbuses and Jumbo Jets to be effortlessly coordinat-ed between park, take-off and landing positions. The powerful and compact tug’s gripper arm attaches to the aircraft’s nose wheel, a hydraulic platform lifts it, and the tug tows the aircraft to the required position.

A tug with a powerful diesel heart

A piggy-back weighing tons, the aircraft trailing way behind the tug with only a “Follow Me” ve-hicle to show the way – this re-quires a powerful engine! With the DEUTZ TCD 2012 L06, the tugs are equipped with a pow-erful diesel heart. Available in robust 4 and 6 in-line cylinder versions, the water-cooled 2012 engine is characterized by a high

power density of 67 – 155 kW at 2,400 rpm and complies with emission standards for mobile machinery according to EU-Non-road 2004/26/EU Stage IIIA and US EPA Tier 3. The slender en-gine design also provides maxi-mum flexibility. The TCD 2012 is also economic through the DEUTZ high pressure injection common rail system (DCR®).

Pushback vehicles with DEUTZ TCD 2012 engines

The so-called pushbacks can also be performed by aircraft tugs. A pushback manoeuvre is

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21

Technology

For most people airport atmospheres trigger feelings of wonderment. Within the large halls and long walkways

you soon get that familiar holiday feeling, and a glance towards the planes landing and departing makes you long

to get away. But for arrivals and departures to function smoothly, a lot of behind the scenes support is required.

DEUTZ LIVE took a look at the Leipzig/Halle Airport and discovered that this airport also relies on tried and

tested DEUTZ expertise.

required for aircraft which are nosed at the boarding gates. The majority of jet aircraft are unable, or are not permitted, to reverse under their own power. Aircraft are also often posi-tioned where they are unable to turn by themselves, especially at major airports. JBT-Aerotech also use the DEUTZ TCD 2012 to power the two pushback ve-hicles in service at the Leipzig/Halle Airport. There are two pushback methods. Either a push bar, similar to a tow bar, is used or a nose tug is employed which, similar to a normal tug, attaches to the nose wheel. This

enables much faster moving of the aircraft. The aircraft is then pushed onto a taxiway where it can then proceed to take-off un-der its own power. This is a de-manding task for the tug engines because the aircraft’s turbines start-up during pushback and as soon as there is enough dis-tance from the departure build-ing. This is necessary so that the aircraft can then quickly exit the taxiway.

Leipzig/Halle Airport as a European hub for DHL

The Leipzig/Halle Airport is not

just important for passenger aircraft. In 2008 the Deutsche Post World Net, decided to use Leipzig/Halle as their European DHL hub. The central German airport then became one of the most important freight hubs in Europe. Around 50 DHL cargo aircraft use the Leipzig/Halle Air-port daily, and nothing functions without DEUTZ. DHL recently or-dered a further 98 Mulag tugs to add to the existing fleet of 150. These aircraft tugs, which ensure the forwarding of several hundreds of postal containers every day, are also equipped with the DEUTZ TCD 2012. $P

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Rubrik

22 DEUTZLIVE 01/201022 DEUTZLIVE 01/2010

Life

For the inland state of nearly 30 million inhabitants, with many living in the Himalayan region, each day poses fresh challen-

ges. There are more than 16 hours of power cuts daily, and this in a country where more than forty percent live above

3,000m. The majority of Nepa-lese, around 85%, live on the land with 15% being urban dwel-lers. The most populated centre remains the Kathmandu valley, where nothing functions wit-hout energy supplies. It is not just the banks and offices that require a guaranteed supply of energy, but also the hotel sector - Nepal is a magnet for tourists. Around 300,000 people travel to Nepal each year with tourism bringing in €50m, around 30% of total income. Temperature and air pressure represent daily challenges to humans and ma-chines alike in a country where some regions even today remain undeveloped. The air cooled DEUTZ 914 series engines are the insider tip for this mountai-

nous region. They are easy to use and extremely economical. Furthermore, the robust DEUTZ engines can always be depen-

ded on irrespective of the mon-soon climate temperatures ran-ging between -20°C to +32°C. The engines are equipped with an extra kit that is adapted to the region in which they are to be used. There are specific kits for desert applications, for use in artic conditions or for tropical heat and humidity conditions. The air cooled DEUTZ engines in the gensets are available in performance classes from 29 to 152 kVA. Gensets with DEUTZ engines are a real alternative in the Nepalese market because demand for energy there is con-tinuously growing. A supply grid caters for the major centres where energy is required, and hydroelectric plants feed an additional 550 megawatts into

Between the world’s most highly populated states, the autonomous region of Tibet’s People’s Republic of China

in the north, and India in the south, west and east, is the state of Nepal, on average the world’s highest

country. To the north and east lie a major section of the Himalaya range including Mount Everest, whose summit

at 8,848 m above sea level is the highest point on earth, as well as seven other of the world’s highest peaks. In

this country, whose climate poses many challenges, DEUTZ has a presence with its air-cooled engines

that provide reliable local energy supplies as diesel gensets..

DEUTZ at the top of world

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23

Press newsDecember 2009 – April 2010

READER ACTIVITY | Prize game

What is shown in this close-up photograph?

A) TCD 3.6 L4 B) Roller C) Tug D) Burner

Send your answers via e-mail to decker.j@deutz.com or by fax to +49 (0)221 822 15 24 93. Closing date is 15 June 2010.

From the correct entries we will draw winners for an A5 leather writing case.

Winners of the prize draw from edition 2/2009: AdBlue-Tank

Winner: Roland Goller, Kurt-Schumacherstr. 11, 95326 Kulmbach, Germany

Service

the network But this still does not guarantee an uninterrupted energy supply. Rohini Tapaliya, president of the German-Nepa-lese board of trade, introduced the air cooled engines exclusi-vely into the local market with a genset launch in November 2009. $P

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Take part and win: This time an A5 leather writing case with an exclusive DEUTZ logo beckons the winner.

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