powernews

Full spectrum
Perkins new engine completes the 1100 Series
Full spectrum
Perkins new engine completes the 1100 Series
Volume 15 issue 3 News from Perkins Engines Company Ltd, the leader in off-highway engine technology November 2005
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So were moving towards the end of another
year, which is signified not only by shops
selling Christmas cards and cakes three
months before the big day, but by the fact
that Agritechnica 2005 is upon us once
more.
The exhibition, which is being held at the
Hanover Exhibition Grounds, Germany, at
the start of November, bills itself as the
worlds leading exhibition for agricultural
machinery. It is held every other year, and
figures from 2003 show that nearly 1,500
companies from around the globe were
there exhibiting their wares last time round.
Foreword
Opportunity knocks as
2005 comes to a close
Contents
powernews
I
v ol u me 15 i s s u e 3
COVER STORY
Published by Perkins Engines Company Limited
Editor Ian Manley
All communications should be sent to The Editor,
Powernews, Perkins Engines, Company Limited,
Eastfield, Peterborough, England PE1 5NA
Telephone +44 (0) 1733 582185
Fax +44 (0) 1733 582655
Web site www.perkins.com
Editorial policy The opinions expressed in Powernews
are not necessarily those of the Editor or of Perkins
Engines Company Limited.
Design editorialanddesign.com
3
Converted to gas
A special report on how Perkins Dutch distributor,
Kemper en Van Twist, is leading the way in the
application of gas-engine technology with
a string of innovative applications. 14
Full spectrum
The new Perkins 1103D
has cemented the
companys position as
a global solutions
provider with a truly
comprehensive
engine range.

One of the big topics in Europe
at the moment is that of
bio-fuels. Germany seems to
be leading the debate on this
critical issue...
Of course Perkins was one of those
exhibitors, and will be again in 2005.
One of the big topics in Europe at the
moment is that of bio-fuels. Germany seems to
be leading the debate on this critical issue, and a
specially commissioned article on page 10 gives
the full story on the bio-diesel revolution.
And of course, Powernews wouldnt be
Powernews without the launch of a new
Perkins engine the 1103D. Read all about
this fabulous new power unit on page 12.
As this edition shows there are a wide and
diverse number of OEMs who choose
Perkins for their power source.
So turn the page and start to find out even
more about Perkins, its products and its
people.
Ian Manley, editor
New innovations
The latest news on innovative Perkins-powered agricultural,
construction and power generation applications from leading
manufacturers such as Lindner, Dynapac and Weidemann.
12
News
A round-up of news and developments
from Perkins, its customers and its
distributors, including a dream come true
for Turkish OEM Erkunt as the first
tractors it has manufactured roll off the
production line. p4-9
Briefing
Its always been easy to identify which part
you need for your Perkins engine, but now
its even easier thanks to the launch of a
new software system. p5
Spotlight
Powernews reports on a Perkins triumph
in the fast and furious world of
competitive tractor pulling. p7
Marine news
How a new Perkins-Sabre engine, the
M92B, is meeting both customer
performance demands and key
navigational regulations. p9
And finally
A report on the ways in which Perkins
Applications Engineering, Dealer and
Distribution department works closely
with the distribution network to ensure
that the latest technical knowledge and
engine advancements are shared between
both parties. p19
Tiger, tiger, burning bright
Powernews profiles Antonio Carraro, an Italian
manufacturer that has been supplying its
Tigre tractors for more than a century. 16
Bio-fuels - the future
Industry expert Norman Dunn looks at how
Germany is leading the development of
petroleum substitutes that can reduce
global warming while securing new earning
possibilities for crop growers.
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BRIEFING
Its always been easy to identify which part
you need for your Perkins engine, but now
its even easier thanks to the launch of a new
software system. Here, Powernews takes
you through the main features and benefits.
Perkins is set to launch SPI
2
in November, and the new
enhanced system offers a wealth of benefits to distributors and
end users alike.
The original SPI (Service Parts Information) and its sister
system, SPI-Lite, have become key tools for distributors and
dealers in helping end customers service their applications.
The new SPI
2
takes the best of both these packages and adds
even more. Sam Evans, SPI
2
specialist, said the key objective
has always been to get the customers machine up and running
as quickly as possible by making parts identification easier and
faster.
Perkins has a long history of selling diesel engines, and this
system captures just about all the engine information required
to support them. When you look at the size of our database,
you realise that that equates to a huge amount of information!
he said.
SPI
2
contains 30,000 build lists, 125,000 part numbers,
35,000 graphics and 500 documents detailing everything you
could ever need to know about a Perkins engine.
Earlier systems were only updated every six months. In
order to keep the network up to date all the data stored
within SPI
2
can be updated via the internet. There are also
plans to introduce an on-line version of SPI
2
, which will be
updated on virtually a daily basis.
The Perkins engine range is moving so fast with new
engines and new technology. Its just as important for our
product support systems to keep up to date, Sam said.
The build list is the best way to find the right part for a
customers engine, but not everyone has this information to
hand.
SPI
2
can find parts using casting numbers and engine serial
numbers for the first time. These new searches mean that
there will be more than one way to find the
right information, which means the
customer is more likely to get the right
part, first time.
With engine ranges like the 4.236
being in production for more than 30
years, its not surprising that, as
technology develops, improvements to
the range are undertaken.
SPI
2
helps ensure the customer gets the
most up to date parts for their engine
through its supersession function.
This tracks any changes to the
product, no matter how small, to make
sure that the customer gets the
correct part.
Fast response: Sam Evans, SPI
2
specialist,
says that the new software will help to
get the customers machine up and
running as quickly as possible.
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Switzerland
4
Export institute praises
Perkins training focus
Perkins has won a prestigious industry
award in recognition of its commitment to
staff training.
The company was honoured with the
Institute of Exports Export Training Award
at its annual gala awards dinner in
Birmingham, England.
The award was presented for Perkins
introduction of a series of innovative training
schemes for its staff during 2005, which
covered a range of export-related topics.
The company worked closely with the
Institute of Export in the planning and
delivery of courses, to ensure that they were
tailor-made for the Perkins team.
Working with the Institute of Export and
other professional bodies, Perkins also
initiated a credit management conference,
providing a forum for employees and various
partners alike.
Perkins credit risk manager Stewart
Fairbairn said: We really see this as just the
beginning for us, as far as training is
concerned. Our European colleagues in
Geneva are very interested in what we have
done so far, and it is really a question now of
keeping the momentum going.
It is wonderful to be able to offer our
staff these training opportunities, and they
certainly seem to be gaining a lot from it.
Receiving this award from the Institute of
Export certainly makes all our efforts
worthwhile.
Now in their second year, the Institute of
Exports annual awards are a celebration of
exporting excellence and are supported by
Barclays and UK Trade & Investment.
The Export Training award, sponsored by
Eversheds, honours the organisation which,
in the opinion of the judges, recognises the
benefits of international trade training and
demonstrates this by arranging and providing
a planned approach and a suitable
programme on an ongoing basis.
Chairman of the Institute of Export Andy
Nemes said: We are delighted to honour
the team at Perkins Engines with this award.
They are a shining example of the
commitment to training and professionalism
championed by the Institute of Export.
Minelli sets up
diesel academy
Winning formula: The Perkins team collect their award (l-r) Dixie Cambridge, Raymond McMorran,
Deborah McAteer, Stewart Fairbairn, John Grayston of award sponsor Eversheds, and President of the
Institute of Export, Sir Martin Laing
Power, efficiency, quality and
control. These are the words
combine manufacturer
Semanatoarea uses to describe its
machines.
But these words are also the
reason why the Romanian
company has chosen Perkins to
power its complete range.
Perkins 1106C-E60TA six-
cylinder power unit meets the
farmers needs in terms of power
and reliability, as well as meeting
the relevant emission legislations.
The Dropia harvesting combine
with mechanical transmission
comes in two ranges - the 1120
and 1430. Semanatoarea has paid
close attention to designing the
application to ensure that it
satisfies even the most demanding
customer in terms of robustness,
productivity and servicing
intervals.
Both the Gloria 1120 and 1420
harvesters come with hydrostatic
transmission. These units set new
quality standards with increased
control, safety, speed and
efficiency.
Perkins Swiss distributor has set up
its own Diesel Academy for
engineers and mechanics working
throughout Switzerland.
More than sixty engineers have
graduated from the inaugural course,
which was held at Minelli AGs
headquarters in Pfaeffikon.
The course was open to young
engineers and apprentices who work
on agricultural or construction
applications, and focused on Perkins
new electronic engines. During the
day the participants learned about the
features and benefits of the Perkins
1100 Series, and gained an
understanding of some of the
servicing issues relating to the
engines.
Minelli has a great depth of
knowledge when it comes to the
1100 Series engines. Its engineering
department has developed a range of
specialised diesel and gas-powered
applications, including hydraulic
power systems, CHP (Combined
Heat and Power) and supercharger-
and cable winch-power systems, all
using the Perkins 1104C-44 and
1104C-44T power units.
The company produces complete
customer-specific powerpacks for use
in applications such as power
generation or fire-extinguisher pumps.
As well as marketing its own
applications, Minelli also provides
support to Perkins customers
throughout Switzerland and
Liechtenstein with engine sales and
next-day delivery of spare parts.
A powerful combination
drives growth in Romania
Academy reward: Young engineers get to
grip with the Perkins engine.
Power packed: The Dropia combine is powered by Perkins 1106C Series engine.
Allam Marine has been
appointed as a Perkins Engines
Gas Partner to supply gas-
powered generating sets.
Under the deal Allam Marine,
the Hull-based gen set specialists,
will package and ship the engine
with the necessary parts to
transform the power unit into a
gen set. This will then be
assembled, sold and serviced in
Nigeria by local partner Mikano.
Perkins and Allam Marine have a
long relationship with diesel-
powered engines, but Dave
Robinson, Perkins sales manager for
Electrical Power, confirmed this was
the first move into the gas market.
This is a really exciting
development for all parties, and
builds on the superb working
relationship we have established
with Allam Marine over the last
13 years, he said.
Perkins appoints Allam
Marine as gas partner
5
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A 50-year dream has now become a reality
for Erkunt.
The Turkish company was established in
1953 as a casting and pattern shop. The
Ankara-based organisation started to expand its
operations by machining its castings and now
supplies, amongst others, fully machined
transmission housings for Turners and cylinder
heads for Perkins.
Mumin Erkunt, founder and chairman of the
company, has now realised his long-term goal
by producing the companys first range of
tractors.
The striking tractors come in 60, 70 and
80hp variants, with the option of two- or four-
wheel drive at each power option.
They are all powered by Perkins 1103-33(T)
Series engines. These offer Stage 1 and Stage 2
emissions compliance, excellently suited to the
Turkish and Mediterranean markets where the
machines are to be sold.
The Perkins power unit is linked to a ZF
transmission system, with the transmission,
back axle and front bolster linkage system
designed by Austrian tractor experts,
Lindner.
Paul Rogerson, Perkins
business development
manager, said Erkunt chose
the Perkins power unit
because of its high brand
presence and reputation in the
Turkish marketplace.
And he added that Perkins
experience and standing in the market has been
utilised to help bring this exciting new range of
tractors to the market: Perkins application
engineering team has worked closely with
Erkunt to develop this tractor, he said.
Weve also offered advice and suggestions
for Erkunts brand development, as well as
establishing the aftermarket support network.
This has been done with the help of Perkins
Turkish distributor Ilkerler. The company,
which has six Super Dealers and 16 Parts and
Service Dealers across Turkey, has helped to
provide an aftermarket support package to
meet Erkunts, and its customers,
requirements.
BU Power Systems has been appointed as
Perkins sole distributor in Germany.
With its headquarters in Osnabrueck, the
company has branches in North, East,
South, West and Central Germany.
Each of the five Power Centres is
kitted out with a state-of-the-art
workshop and a fleet of service vans complete
with laptops, electronic diagnostic tools and
specialist tooling and, of course, a highly
qualified service engineer to respond to any
problems.
BU Power Systems extensive network means
that it can reach and help all customers across all
applications - from material handling and
agricultural applications to industrial equipment.
Norbert Schuchert, general manager Perkins
Motoren GmbH, said: Product support is fast
becoming the deciding factor for customers
when they are looking to purchase an engine.
In addition to this, increasingly tough
emissions legislation means that expert engine
care and servicing is called for.
Perkins believes that BU Power Systems will
be able to offer the highest level of service to
our customers and satisfy all of their needs,
ranging from offering genuine Perkins parts and
repairs to new engine sales.
Double delight
Weidemann has introduced two
wheeled loaders to its line up.
The Hoftrac 1350 CX45 and
Hoftrac 1370 CX50 combine quality
with a modern design. The end result
is two new units that offer driving and
operating comfort together with a
high level of functionality.
Both models have extensive
standard equipment, and a hydraulic
quick-change system for the speedy
changing of accessories.
A new axle design provides
effective thrust force transmission
while keeping the load on the
differential and axle shafts low.
And the Perkins 404C-22 engines
offer the perfect power ratings
coupled with reliability and excellent
fuel consumption.
Germany
North America
BUPS appointed as sole contact
SPOTLIGHT
Uplifting
experience: the
Hoftrac 1370.
Erkunts dream
becomes reality
Perkins has proved that its engines are more than up to the
toughest challenge after a Perkins-powered machine was crowned as
Italys tractor pulling champion.
Tractor pulling is a highly competitive sport in Italy, which makes it
even more impressive that the Moretti brothers scooped the title for
the second year running.
And whats more, their machine was so superior that it won the
2005 championship with one race to spare!
The Morettis have developed the standard 130 hp six-cylinder
Perkins (1000 Series) engine to produce more than 900 horsepower
at 5000 rev/min.
With the help of Italian tractor manufacturer Landini they made
sure that their beast, the appropriately named Buffalo, was set for
the peak of performance.
The sport of tractor pulling sees tractors of up to a massive
8000hp racing down a 100m long competition track.
The challenge comes from the fact that the tractors are pulling a
special trailer, which carries weights of up to 20 tons!
The trailer is designed with normal wheels at the rear and a
runner on the front.
On the top is the weight, which slowly moves to the front of the
trailer as the tractor accelerates, thus making the trailer heavier and
slowing it down.
The point of the competition is to be the tractor that pulls the
heaviest weight the longest distance.
The sport is not just limited to Italy. In Germany Rudi Plattner and
Team Super Moni are on the way to mirroring the Morettis
success.
Rudi started tractor pulling 18 years ago, and has been using a
Massey Ferguson Tractor Typ 1155 powered with a V8 Perkins
Engine since 1992.
The engine has three turbo chargers and a methanol injection
which increase the original power from 155hp to a staggering
2500hp, and 7000 rev/min.
He was crowned German champion last year, and at the time of
Powernews going to press he was well on his way to reclaiming the
trophy.
Mighty effort: the Moretti team pulls its way to the championship.
A Perkins engine has just come out on top in
the fast and furious world of tractor pulling.
Powernews reports on a thrilling finale.
Truck solution
Truck drivers can now keep warm, or
cool, overnight without having to run
their engine.
Dometic Corporation and Temco
Metal Products Company have
developed an integrated auxiliary
HVAC and power generation system
for trucks.
Marketed under the Idle Solutions
name, the product provides air
conditioning and heating for the
sleeper and power for on-board
electrical appliances when the trucks
engine is not running.
A three-cylinder liquid-cooled 15.8
hp Perkins diesel engine drives a 7.8
KW generator, although the system
has been designed to work with any
gen set.
Things are set to change at
Perkins Dutch distributor,
Kemper en Van Twist, with Jurrin
Broos retiring as managing
director following an impressive
career.
Jurrin joined the family-owned
company in 1965 as a technical
commercial commercial clerk, and
held a range of posts during his
career before becoming managing
director in 1985.
Throughout my whole career
the Van Twist family has given me
the opportunity to develop myself
and my career, he said.
Ive really enjoyed creating
solutions and proposing new ideas.
The market has changed rapidly,
and we have always adapted to
keep ahead of those changes.
We did it as a team. My role
was to create ideas and to support
people. I think that that is the true
role of a manager these days, you
cant do it all yourself, you depend
on good team work.
Jurrin is to be replaced by Rob
Van Twist, representing the fifth
generation of KVT.
Rob was managing director of
KVT up until 1985, when he
handed over to Jurrin so he could
concentrate on the groups other
business interests.
Rob paid tribute to Jurrin and
his dedication over the years.
Hes worked for the company
as if it was his own, he said.
That gave me the feeling that I
didnt need to be closely involved
with the company as I was
confident that the responsibility
was with the right person.
Changes at the top
for Dutch distributor
Handing over: Jurrin Broos, left, is
passing over the reins to Rob Van
Twist.
On the line: The new Erkunt tractor in production.
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Indonesia
MARINE NEWS
The new naturally aspirated Perkins Sabre M92B is being
heralded as the first marine propulsion engine to be certified as
complying with Central Commission for Navigation on the
Rhine Stage Two requirements.
This set of regulations does not come into force until January
2007, which means that the new direct injection, four-cylinder
engine complies with all European marine environmental
legislation until 2011.
The new 4.4-litre engine supersedes the Perkins Sabre M92,
and its environmental credentials are all the more impressive
for its being a naturally aspirated engine.
Such performance is normally regarded as being the preserve
of turbocharged electronic engines. It is based on the new, high-
durability Perkins 1100 Series engine and develops its maximum
power at a comfortable and low stressed 2,400rpm. The M92B
is 3dBA quieter than the M92 and six per cent more fuel
efficient. It offers 500-hour service intervals and has a standard
two-year warranty, with three years on major components.
The M92B is also fully compliant with the European Stage II
gaseous and particulate pollutant emissions regulations and the
US Environmental Protection Agencys Tier Two regulations. It
is also capable of conforming with the ECs Recreational Craft
Directive.
In terms of size it is very similar to the original Perkins Sabre
M92. This adds to its appeal as a re-power option for a host of
craft, including inland waterway and coastal cruisers, sailing
yachts, passenger ferries, fishing boats and workboats, whether
replacing an M92 or the earlier Perkins M90/4.236 engine.
Standard transmission options for the new engine are the Hurth
HSW 450A, the Newage PRM 500D or the Borg Warner 72CR
gearbox.
A new Perkins-Sabre engine is meeting both
customer performance demands and key
navigational regulations. Powernews reports
on the main benefits of the M92B.
8 9
2005 is a momentous year for
Austrian alpine application
manufacturer Lindner.
The companys 10,000th
Geotrac tractor is due to leave
the production line this autumn,
while the highly popular Unitrac
transporter, has reached the
1,000 mark. And as if that wasnt
enough, the family company has
also been celebrating its 40-year
history with Perkins, its sole
supplier of engines.
Owners Hermann and Stefan
Lindner visited Perkins
headquarters in Peterborough,
England, to celebrate this 40th
anniversary.
Speaking at the official
celebration Hermann Lindner
said: We are very proud to
have such a good supplier in
Perkins. We are a small factory
and our philosophy is to use
main parts from quality
suppliers such as Perkins for
engines, ZF for gearboxes and
so on.
Linders success is clear from
its strong position within
Austria. With a market share of
more than 15 per cent for
standard tractors, it has
strengthened its third position
in the Austrian tractor ranking.
Wave of approval
The Perkins Sabre M92 is proving a popular
addition to the marine marketplace.
Dynapacs new range of small tandem
rollers are proving to be a real hit.
Demand for the CC800, CC900 and
CC1000 models has outstripped the
predictions made when the products were
first launched in 2004.
Powered by the powerful yet quiet Perkins
403C-11 engine, this range represents
Dynapacs latest introduction of the one-
metre and below range of rollers.
The models have drum widths of 800 mm,
900 mm and 1000 mm respectively, and
operating weights of around 1600 kgs,
making them ideal for small compaction
jobs such as footpaths and cycle tracks.
While they are designed primarily for
compacting asphalt, their compaction
performance means they are also suitable
for thin soil layers.
The water-cooled, three cylinder Perkins
403C-11 engine provides 17 kW (23 hp) of
compact power. The machine noise level is
very low enabling an improved working
environment for users, while the spacious
operators platform, isolated from
vibrations, ensures the best possible
working station.
In line with Dynapacs relentless focus on
quality, reliability and ease of maintenance,
the machines feature long service intervals
with easily accessible service points, which
include a maintenance-free steering hitch
and steering cylinder.
A new addition to the range, the CC900S,
has also recently been added which
features a single arm attachment to the
drum. This allows the right side of the
front drum to be used for compaction
close to walls.
Dynapac rolls
out new models
On a roll: Dynapacs
CC900 machine.
Above: More than a quarter of all Geotrac tractors are exported. Below:
(from left) Stefan and Hermann Lindner exchange gifts with Mike
Francis, Perkins' sales director, to mark the 40-year relationship.
A momentous year for
Alpine manufacturer
A Perkins powered generator will be keeping trainee train drivers
warm in Salisbury, England.
South West Trains has converted one of its Bubblecar engines
for use as a driver training vehicle.
The work was carried out at LNWR Crewe Carriage Sheds. All
seating was removed and three bench seats were fitted at each
end behind the front cab windows, providing room for up to 11
trainees.
The new Perkins generator has been installed for heating and an
electric windscreen wiper was fitted to the central system.
Trainee drivers feel the heat
Sweet success for
irrigation system
Sugar Group Company is the biggest
sugar cane plantation and sugar
industry in Indonesia, with three
sugar plantations, three sugar
factories and one ethanol factory in
Lampung Province, Sumatera Island,
Indonesia.
The cane field covers 65,000 Ha,
with a further 10,000 Ha under
development. In 2003 drought
decreased yield by up to 20 per cent,
and so in 2004 Sugar Group looked
for a new irrigation system, and
turned to Perkins for help.
PT.Traktor Nusantara, Perkins
distributor in Indonesia since 1976,
together with PT.Detracon Prima
Intra., answered Sugar Groups needs
for an effective irrigation system.
A Perkins 1006-6T (IOPU) engine
producing 159 HP coupled with an
AMT Pump has raised 40 litres of
water a second, with two pressure
guns irrigating 50m radius each.
Since 1993 PT.Traktor Nusantara
has supplied 126 T4.236 and 1004-4T
engines with single gun irrigation. And
from 2004 the company has delivered
a number of Perkins 1006-6T (IOPU)
engines, taking the current Perkins
population to more than 450 units.
The results are obvious -
production was running at 450,000
tons of sugar in 2004, leaving Sugar
Group extremely satisfied with the
performance, productivity, and
efficient running cost of the engines,
as well as the excellent product
support from PT.Traktor Nusantara as
Perkins distributor.
Water front: The Perkins powered
irrigation system has helped drastically
increase yield.
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10 11
A
n oil boom far away from the North
Sea wells will see 1.95 million tonnes
of RME (rape methyl ester) processed
from German-grown oilseed rape and flowing
into fuel tanks this year.
At the same time five major bioethanol
plants are now producing petroleum
substitute in Europe. Wheat and sugar beet
are the main raw materials in this case and
the latest plant in Germany will be converting
600,000 tonnes of grain to environmentally-
friendly fuel in the next 12 months.
Theres certainly a demand. France, Spain,
the Netherlands and Germany are already
adding RME and bioethanol to conventional
diesel and petrol. Some rural bus services in
France, for example, now use a 30 per cent
RME mix for their vehicles. In Germany the
RME diesel substitute is proving increasingly
popular unmixed as a pure fuel at the pumps.
Major car makers have given the go-ahead
for RME and bioethanol as fuels in many of
their engines, as have the worlds main tractor
manufacturers including Case IH, Claas,
Massey Ferguson, John Deere and Fendt.
While Germany has encouraged sales by
removing mineral oil tax from biofuels at the
pumps, the Berlin government has also used
tax policies to boost fuel from the fields in
another way: it has stopped tax rebates on
agricultural fuel.
This means that instead of paying just 25
per cent of the street price ( EUR 1.15 or
0.79/l in October, 2005) as they did just a
year ago, farmers now receive only a 16c/l
refund for the first 8,370 litres of
conventional diesel used per year on each
farm.
Meanwhile, out on the autobahn, RME
diesel sales increased by 32 per cent in 2004
boosted by the spiralling price of conventional
diesel at the pumps where cost per litre more
than doubled in the last five years. Over
1,800 filling stations in Germany now offer
the biodiesel alternative.
But the trouble with RME is that it is
expensive to produce. Despite being
homegrown and not taxed, it was selling in
autumn 2005 at 95 c/l, just 17 per cent less
than conventional diesel. Much more attractive
to farmers is the unprocessed product from
oilseed rape: simply cold-pressed and filtered
before going into the tank.
This fuel is available at almost half the price
of conventional diesel or around 60c/litre and
can even be produced right on the farm.
Another bonus: the remaining solids after
crushing constitute a valuable 40 per cent
protein feed for livestock.
There are a few catches, however.
Standard diesel engines have to be converted
for the high-viscosity fuel. The current cost
for this work, which can include fuel-tank
heaters to increase the flow properties of the
cold-pressed oil along with higher capacity
fuel lines, filters, fuel pumps and injector
nozzles, is between EUR 2,300 and EUR
6,000 per tractor engine. This means real
savings are only apparent when diesel
consumption on the farm crosses the
10,000-litre mark.
But recent research indicates that every
month hundreds of German landowners are
now taking the cold-pressed biofuel route.
Adding to the enthusiasm are grants of up
to 60 per cent to help with conversion
costs. State aid in Lower Saxony of EUR
80,000 for this purpose was used-up in just
five days this year!
This welcoming reaction is surprising
some people because there were
discouraging results from a recent
government 110-tractor test looking into
tractor engine performance on the pure
vegetable oil. Over the test period only 31
engines came through without mechanical
problems, although 70 of the damaged
engines required comparatively small
repairs costing below EUR 1800. Causes
included blocked filters and injection
nozzles, increased waste deposits in the
engines and increased wear.
Here, the German government has
stepped in smartly with EUR 23 million for
a research project looking into ways of
improving vegetable oil fuels of the future,
especially for the engines of tractors and
other farm machinery.
Meanwhile the versatile pioneer farmers,
backed by their agricultural engineers, have
been using their experiences to set out
their own guidelines to engine survival.
Increased filtering of the oil prior to
tanking is now practiced overall and in fact
there are laboratory services now available
for checking that samples of pure oil meet
the so-called Weihenstephan Standard
which is soon to be translated into an
international industrial purity norm. Current
price for a full oil analysis: EUR 250.
Of course the main aim of RME, cold-
pressed oil and bioethanol as fuels is to help
reduce the output of climate-changing CO2
and other emission gases from internal
combustion engines. In the case of the
biofuels, the CO2 produced is mainly
reabsorbed by growing the crops required
for their production in the first place.
But another biofuel on the horizon is
offering even more improvements in this
context as well as in energy efficiency. This
is the new SunDiesel featuring Biomass-
to-liquid (BTL) technology and produced,
not from grain or oilseeds, but from a wide
range of by-products including straw,
unwanted grass silage or hedge clippings.
SunDiesel can be used in any conventional
diesel engine without conversion work and
has, according to a EUCAR study, a 90 per
cent CO2 reduction potential compared
with biodiesels 50 per cent. Both
DaimlerChrysler and Volkswagen are
running pilot projects with Sun Diesel - yet
another fuel from the fields being developed
in Germany to offer the world cleaner, more
efficient, regenerative energy sources.
Industry expert Norman Dunn looks at how
Germany is leading the development of
petroleum substitutes that reduce global warming
while securing new earning possibilities for growers.
Bio signs
Meanwhile the
versatile pioneer
farmers, backed by
their agricultural
engineers, have been
using their experiences
to set out their own
guidelines to engine
survival.
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12 13
The new 3-cylinder 1103D engine marks the range
completion of the 1100 Series and offers OEMs a full
spectrum of Tier 3 engines spanning 37.5kW to 205kW.
The 1103D will be available in three variants naturally
aspirated, turbo charged and turbo air-to-air charge cooled
offering a choice of outputs from 37.5kW for the naturally
aspirated model to 65kW for the 1103D-33TA version.
The 1103s seamless progression from Tier 2 to Tier 3,
which comes into force in January 2008 for the sub-75kW
sector, has been made without recourse to electronics.
Instead the 1103D is a mechanical engine equipped with
advanced Tier 3 combustion technology featuring a two
valve head and rotary FIE.
With little or no change to the engine envelope OEMs
will face minimal disruption as they make the transition
from the old emissions regime to the new levels of
compliance. Tom Nankervis, Tier 3 marketing manager, said
that major hook-up points are identical. And with minimal
impact on heat rejection this means minimal additional
re-engineering costs and little disruption to the OEM
production line.
On top of this the use of many common components
reduces parts variety, inventory levels and servicing costs.
These are all tangible benefits that can be passed on to the
end user and their servicing outlets, he said.
This not only smooths the changeover for OEMs but
also allows the development of a clear product strategy.
In the field the 1103D promises low operating costs with
comparative fuel economy to its Tier 2 predecessor without
compromising power and torque delivery.
Indeed there is 12 per cent more power available in the
new TA version up to 65kW - than in the most powerful
Tier 2 predecessor.
In all probability it will be the OEMs customers who will
really experience the difference in the new engines. They
will see gains in machine performance and productivity from
the improved power to weight ratio of the 1103D Series, as
well as feeling the increased usability from the extra torque
on offer.
Our target was to bring extra value to our OEM
customers aside from pure emissions, Tom said.
The 1103D represents a real leap forward in that
respect. It gives more power, optimised fuel consumption
from a quieter, more refined package that provides easy
changeover. It really is a case of providing a complete
solution to the OEM.
The addition of the 1103D means that OEMs can now
benefit from a single three-cylinder platform that caters for
both non- and highly-regulated markets, and everything in
between.
From the 1103A for non-regulated territories to the
1103D for the forthcoming Tier 3 countries, Perkins is
providing an engine solution that has global acceptability and
applications.
We believe an OEMs product range will be enhanced by
Perkins offering more engine variants but from common
platforms so maximising convenience while reducing cost,
Tom said.
Take for example manufacturers in Turkey. Because of
Turkeys geographical location OEMs there can produce
machines for three markets; its own Tier 1 market, Tier 2
markets to the West and the non-regulated markets to the
East. The adoption of the 1100 Series will facilitate that kind
of manufacturing strategy. And whats more it is a strategy
that can be rolled out worldwide for OEMs looking for a
global marketplace.
1103D
The launch of the new Perkins 1103D engine not only completes
the 1100 Series offering, but also cements Perkins position as a
global engine provider with a comprehensive range of options.
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14 15
Wherever you are in the world, if you
ask an engine expert what Perkins means
to them the answer will usually be diesel
engines.
But if you ask the same question in
the Netherlands you may get an
interesting variation on the response:
gas engines.
Holland, and specifically Kemper en
Van Twist (KVT), Perkins Dutch
distributor, is leading the way when it
comes to gas-powered engines.
Rob Van Twist, the fifth generation of
the Van Twist family, said that the
concept of gas power first became
popular in Holland during the Second
World War.
Petrol was scarce for personal use,
and so KVT developed a gas system for
personal cars that was based on liquid
coal gas, he explained.
We had a very large compressor
station with a pressure of 400
atmospheres to turn the coal gas into
liquid.
The second element in the emergence
of the gas market came in the 1970s,
when the country discovered that it was
rich in natural gas reserves.
Since the mid 1980s the Dordrecht-
based company has been taking the
standard Perkins diesel engine and
converting it to run on natural gas or
liquid propane gas (LPG).
KVT, which is the only Perkins dealer
authorised to carry out diesel-to-gas
conversions, prides itself on its
engineering skills, and has developed its
gas conversion methods in-house.
Leading the programme is Harry
Bouw, KVTs industrial product manager.
Around the start of the 1980s there
was a demand for combined heat and
power engines, and Perkins developed
its 4.236 engine to run on natural gas,
he said.
The quality of that engine was not as
the customers expected, so Perkins
asked if we could help develop the
engine.
Drawing on the wealth of knowledge
already held within the company, Harry
and his team developed the engine to
the standards required by the
marketplace.
And Harry said that this success then
lead to other requests.
We had calls from fork lift truck
manufacturers asking if we could supply
the Perkins engines in LPG. We said of
course we can try, and we developed
the 6.354.4.
These manufacturers already used
the Perkins six-cylinder diesel engines.
They came to us because they wanted
the same engine size so they wouldnt
have to develop a new fork lift design
everything fitted into the same place,
which was the biggest benefit of
converting the existing Perkins model.
From the mid 1990s KVT received the
engines fully built from Perkins, but
without the fuel injection system.
But this changed in 2005 with the
engines being built from scratch, with
Perkins supplying a Complete Knock
Down (CKD) kit.
This way takes us a few days to build
the engine and full-load test it thoroughly
for a number of hours, and we can build
each engine to the customers
specifications after the creation of a
specific customised CKD kit, Harry
explained.
The majority of the basic
components remain the same, but we
do a lot of work to make them suitable
for gas.
KVT has now worked with Perkins to
convert its 1104 Series engine to gas,
and that project is nearing completion.
Were 98 per cent of the way there,
Harry said.
We have to do some final emission
testing before we take them to the
marketplace, but weve already done
more than 7,000 hours of testing in our
workshop. We have a Genset that can
run full-load 24 hours a day, and so
weve put that in the test area to do
some long-run tests.
As well as converting Perkins off-
highway engines, KVT has a proven track
record in gas-powered marine
propulsion.
The Canal Company, which operates a
fleet of sightseeing and party boats
around Amsterdams historic canals, has
chosen the natural gas six-litre Perkins
Sabre M135CNG engine for its fleet of
pleasure cruisers.
These engines are extremely quiet,
with more noise coming from the
hydraulic system than the engine, Harry
said. The engines are converted to run
on natural gas as its lighter than air. If
theres a leak it vaporises and
disappears, compared to LPG which is
heavier than air and so would sink to the
bottom of the boat, and could cause
safety issues.
The boats operate right in the heart
of the city, so of course it is important
that noise and air pollution is kept to a
minimum.
powernews
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customer p r of i l e
Main picture: The gas-powered
cruise boat means tourists enjoy
a quiet, environmentally friendly
tour of Amsterdam.
Smaller pictures from left: The
Perkins Sabre M135CNG
installed in the cruise boat
(middle). Some of the parts
which make up the CKD kit used
to convert diesel engines to gas
(left and right)
Powernews highlights how Perkins Dutch distributor, Kemper en Van Twist, is
leading the way in the application of gas-engine technology. In particular, we
describe a fruitful relationship with a company that runs a fleet of sightseeing and
party boats around the historic and picturesque canal system in Amsterdam.
CONVERTED TO GAS
These engines are
extremely quiet, with
more noise coming
from the hydraulic
system than the
engine...
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The Veneto company, situated in the
heart of North East Italy, deserves the
reputation for innovation that it has
gained throughout its century of
operation.
In 1910 Giovanni Carraro founded the
company, aged just 19, and designed a
revolutionary machine capable of
ploughing, sowing, harrowing and rolling
simultaneously.
With this machine the young
blacksmith was met with an immediate
and extremely positive response.
After the war, drawing on the
engineering know-how in the production
of multifunctional machines, Antonio
Carraro introduced its first Tigre
tractor. This proved to be the first of a
stunning range of tractors that has made
up Antonio Carraros core business ever
since.
In the 1960s, Antonio Carraro decided
to separate from his brothers (who
founded Carraro spa, world leader in the
manufacturing of axles for traditional
tractors) in order to start up his own
business. The key features of the
Antonio Carraro Tigre tractors were
the four large equal wheel drive and the
articulated chassis.
Today the company
invests around five
million Euros a
year in research and development with
the goal of producing tractors for all the
niche markets available.
For the last decade Antonio Carraro
spa has kept its first place position in
Italy for sales and has positioned itself
amongst the top companies in the world
for compact tractors from 20 to 100 HP.
Our brand is synonymous with
quality and innovation in all markets and
it is for this reason that our tractors
dont degenerate even after thousands of
hours of work, said Massimiliano
Carraro, marketing director and third
generation family member.
We are a family business and we
regard our staff as part of the family. We
are a team and every member has to
carry out his job to the best of his
ability.
Thanks to a restructuring of the
company that began in 2000 with the
collaboration of the Porsche Consulting
Group of Stuttgart, Antonio Carraro is a
streamlined company with excellent
performance.
During the manufacturing
reorganisation the Porsche consultants
introduced the Kaizen working ethos
that derives from a Japanese philosophy
developed by Toyota. Its 400-strong
work force now produces 5,700 tractors
a year.
Apart from the standard model,
Antonio Carraro offers its clients a high
degree of personalisation. Our tractors
are made to measure, Carraro said.
We give the purchaser freedom to
create the right characteristics for their
individual needs. We listen to them and
then we meet their demands. We also
pay specific attention to climatic and
territorial conditions.
In 2005 the company launched the
new Tigrone Series, a range of compact
tractors for specialised agriculture and
the maintenance of green areas. These
are robust tractors, capable of carrying
out thousands of hours of work, fitted
with first class ergonomic and comfort
features.
Amongst the Tigrone Series seven
tractors there are the top steering and
articulated models, TN and SN, fitted
with Perkins 400 Series engines.
These models are particularly quiet
and environmentally friendly and operate
in full accordance with the legislation
TIER 2003 EPA UE which will be in
force from 2008.
powernews
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Above: Tigrone Series TN 6500 fitted with turf wheels and a Perkins 404 C-22T (Turbo) engine.
Below left: Massimiliano Carraro, Marketing Director at Antonio Carraro.
A tractor is essential when carrying out a range of tasks from preparing golf
courses to cultivating orchards and snow clearance. And for more than a century
Antonio Carraro has been producing machines to carry out these functions
A ROARING SUCCESS
Right: Tigrone Series SN 6500 with Perkins 404
C-22T Turbo engine.
Below right: Carraro has a rich heritage of
tractor production, as this early model shows.
The engines are compact, high
performance power unity, whose
standard maintenance is minimal
compared with other engines.
The use of the balancer on the 404C-
22T engine (determining solution but
complicated for a super-compact engine)
has increased operator comfort.
Antonio Carraro tractors are sold all
over the world: from the North to the
countries in the Mediterranean area such
as Spain, Portugal and Greece.
There are three subsidiaries: AC Iberica
S.A. (Barcelona Spa), which looks after
the markets in Spain, Portugal, North
Africa, South America; AC America Inc.
(Napa-Ca), for the US market.; AC
Oceania Pty Ltd (Taren Point NSW) for
Australia and New Zealand.
17 16
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Two heads are better than one, so Perkins takes extensive measures to
ensure that the vast knowledge and expertise that exist within the
distribution network are made available for the benefits of all parties.
Powernews spotlights a 33-year-old Bedford coach that is still providing
sterling service on the steep hills of New Zealand thanks to the care and
attention of its operator, Bill Hart, and an ever-reliable Perkins engine.
Team approach
Just the ticket
The last edition of Powernews carried
an article about a 40-year-old Perkins-
powered Transit van.
A few weeks after the magazine was
published a letter made its way to the
Powernews desk from New Zealand.
The letter came from Bill Hart, the
proud owner of a 33-year-old coach that,
as you might have already guessed, is
powered by Perkins!
What makes this Bedford 40-seat
coach extra special is that its still
regularly working.
Bill Hart runs Harts Papakura
Coaches, offering sightseeing tours
around the spectacular scenery of
Auckland on New Zealands North
Island.
Bills brother bought the engine in
1973 from North Eastern Motors in
Newcastle, England, and shipped it back
to New Zealand.
The engine was secondhand back
then, and after stripping it down Bill
fitted it into the vehicle he used for his
school bus service.
When he changed that vehicle he took
the engine with him to the new bus!
In 1983 I bought a Bedford coach
from New Zealand Railways, who used
to run the bus services. It didnt have an
engine in so I pulled the engine out of
the school bus and put in into that one,
he said.
Its been there ever since. I rebuilt it
last year with new pistons and liners and
bearings, and that was about it. The
crankshaft had less than half-a-thousand
wear on it!
Last year Bill was in the UK on holiday,
and went into North Eastern Motors
looking for a new oil pump.
I told them what I was looking for
and that my brother had bought the
engine here off a fellow called Handy,
he said.
There was a guy standing over in the
corner with his back to me, and he
turned round and said that he was
Handy, and that there was no warranty
left on that engine now! They got me the
oil pump and I brought it back in my
suitcase.
The bus is now used regularly for
sightseeing tours, and Bill said the engine
is perfect for the job.
Weve got some pretty steep
gradients, but I can get 16 miles per
gallon which is pretty good, he said.
I bought some airplane seats from an
old Air New Zealand DC8 and fitted
those in the bus. Theyre excellent
because theyre very light, being from an
aircraft, and have saved me half a ton on
the weight, which helps with fuel
economy!
Perkins works closely with its
distribution network to make sure that it
shares the latest technical knowledge and
engine advancements.
But this is not a one-way process. As
well as helping to train its distributors,
Perkins looks to the network to get first
hand knowledge of whats going on in the
marketplace, not least when it comes to
the issue of engine installation.
Perkins Applications Engineering,
Dealer and Distribution department has
run two courses this year to do just that,
bringing together more than 60
distributors from across the world to
share the latest information on engine
installations.
The most knowledge out there is in
the distributor base because they see by
far the most applications, said James
Gardiner, applications team leader.
We learn a lot from them. The
different regions of the world see more of
certain applications. China and Singapore,
for instance, see a high percentage of
pump sets, so distributors from those
areas have a high degree of expertise on
those types of applications.
The courses were split into two parts,
with the first looking at the theory behind
what makes a good installation and how
to select the right engine for the right
application. This two-day session also
looked at other elements such as cooling
package design, air system design,
filtration, engine mounting and vibration.
The remainder of the course was much
more hands on, with machines brought in
for practical testing sessions.
We have machines set up for them
and they spend a day testing the machine,
doing cooling tests and machine
performance tests and looking at practical
example of what makes good and bad
engine installation, James said.
Thats what makes the courses
different. They get goods hands-on
experience, which is the only way to
learn. Engine installation is not something
you can learn from a book, you need
practical experience and the only way you
get that is from working with different
machines.
As well as conducting training courses
James and his three-strong team offer
technical support to distributors and
OEMs when it comes to engine
installation.
When a customer buys an engine we
make sure the engine is OK for the job
its intended for, he said.
We make sure that it has the right
performance levels and meets the
customers needs for fuel consumption,
power, overall driveability and how the
machine responds.
We work with the customer to make
the decision to select and specify the right
product.
Because of the range of distributors
that James and his team work with he
said that his job is constantly varied, with
different applications coming up for
discussion almost every day.
Thats the thing about our role, we
could be talking about an emergency
stand-by generator for a hospital one day,
and the next day discussing how to install
an engine into a minesweeper or an olive
tree shaker!
Smooth operators: Bill Hart next to his
33-year-old Bedford coach that still carries
passengers every day.
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Above: Delegates from the Malaga training session. Smaller pictures from left: Perkins
applications team leader James Gardiner. Alan Hardwick (left) explains the fundamentals of
engine installation. Hands on testing in Singapore. James teaches the theory.
Weve got some
pretty steep
gradients, but I can
get 16 miles per
gallon, which is
pretty good.
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