Swiss high-tech automotive engineering - Motorex

WITH 2010
RACING RESULTS
NO. 91/42 I DECEMBER 2010 I www.motorex.com
REPORT 10
Swiss high-tech automotive engineering
Packed full of high-end hybrid technology, the SWISSAUTO POLO REX is headed
straight for the international automotive market. Fredy Barth drove it for us.
TOPIC 8
LowSAPS technology
FOCUS QTM for
clean snowcats.
INSIDE 14
MOTOREX laboratories
State-of-the-art infrastructure
at your service.
INDUSTRY 18
Medical engineering
Innovative production
for precision forceps.

IN MOTOR SPORT, YOU CAN’T AFFORD
TO MAKE COMPROMISES, HE SAYS.
UNLESS YOU DON’T WANT TO WIN.
WHY DO YOU THINK
HE SWEARS BY US?
Being successful in motorcycle racing is like winning a marathon of 100-metre sprints. Because only if eve-
ryone on the team is performing at peak level can the rider do his best. That’s why Winfried Kerschhaggl, ,
Motor Sport Director KTM / WP, is so uncompromising when it comes to quality. “Promises aren’t enough. .
I need to know that I can rely on someone absolutely.” Making the most exacting demands: that’s some-
thing MOTOREX also stands for. And why we are precisely the right partner for KTM. Find out more about t
how our oils are helping companies from a wide range of industries to reap success: www.motorex.comm
2
Winfried Kerschhaggl, Motor Sport Director KTM / WP

CONTENTS EDITORIAL
NEWS
4 MOTOREX in the news
TOPIC
6 LowSAPS motor oil for snowcats
HYDRAULIC OIL
8 Winter sport regions turn to OEKOSYNT HEES
REPORT
10 Swiss high tech on the international
automotive market
INSIDE
14 The latest from the MOTOREX lab
EXPORT
16 Storm Motor storms Finland
INDUSTRY
18 Innovative production processes for
precision forceps
PRACTICE
20 For heavyweights: GREASE 219
BOX
22 Cool ideas/Did you know…/Comic
IMPRESSUM Editor: BUCHER AG LANGENTHAL I MOTOREX Lubrication I Bern-Zürich-Strasse 31 I CH-4901 Langenthal I Tel. +41 (0)62 919 75 75 I Fax +41 (0)62 919 75 95 I Customer service by phone.
Advice and problem solving also in German, French and Italian I Design, redaction and art direction: AESCHLIMANN, Advertising Concepts and PR GmbH, Muri/Berne I Translation: BMP Translations AG,
Basel I Graphics and prepress: Burki & Scherer AG, Oftringen I Printing: Dietschi AG, Druck & Medien, Olten I Text contributions may be used when source is indicated. I Cover photo: Racer (WTCC series,
SEAT SWISS RACING Team) and test driver Fredy Barth with SWISSAUTO POLO REX I MOTOREX ® and all employed product names are internationally protected trade marks. No responsibility is accepted
for printing errors or changes in the technical data.
MOTOREX MAGAZINE I DECEMBER 2010
Dear customers, partners, readers,
dear colleagues,
MOTOREX
creates value
As early as the first century B.C., the Roman poet Publilius Syrus wrote that
“money alone sets all the world in motion.” In recent years these words have
proved all too true. The world was ruled by unbridled financial markets;
there was speculation and juggling of fantasy products. The equilibrium
between capital and labor vanished altogether. There was more fast money
to be made with financial investments than with honest, value-generating
work. What remained was a dismaying heap of rubble for the government,
and thus for all of us, to clean up. Without real added value there is no benefit
to the economy. One person’s speculative gain is another’s loss. It’s as simple
as that in this zero-sum game!
Our company too has struggled with the global economic crisis during the
past year. But we have never lost sight of our full responsibility as a Swiss
family business. In keeping with our founder’s philosophy, in nearly 100
years we have not lost a single franc to speculation. We have kept our
honestly earned profits in the company, reinvesting for sustainable
growth and to keep our 240 jobs secure. We are pleased and thankful to
have had no layoffs during the difficult times. And now, as the times get
better, we know we can still depend on our loyal employees. Precious
people with potential, initiative and ideas put to use every day through
the work of their hands and minds for MOTOREX. This issue of MOTOREX
magazine presents more about all the things we’ve created, started and
invented for and with our customers.
Please join us today and in the future in celebrating the many win-win
propositions we’ve created for our customers, employees and MOTOREX
businesses.
And please accept my sincerest thanks.
Peter Regenass-Bucher
Chairman of the Board, BUCHER AG LANGENTHAL
3

MOTOREX IN THE
NEWS
UTTO POWER PACKAGE
FOR CONSTRUCTION
EQUIPMENT
The new MOTOREX UTTO CF (Universal
Tractor Transmission Oil) in SAE
10W/30 viscosity is specially designed
for use in heavy-duty construction
machinery and heavy hauling
vehicles. It is ideally suited for filling
axles (especially with self-locking
differentials), transfer case shifters
and transmissions with wet brakes.
It also boasts remarkable thermal
stability and high wear protection
and reduces noise from wet brake/
self-locking differential systems.
MOTOREX UTTO CF meets API GL-4 /
ZF TE-ML 03E, 05F, 17E / KOMATSU
AXO-80 / VOLVO WB 101 / Allison C-4
specifications.
RACING PRO 4T NOW
AVAILABLE IN SAE 5W/30
The recently introduced RACING LINE
racing lubricants for motorbikes have
been a big hit with many motor sport
teams. Now MOTOREX has added
semi- synthetic RACING PRO 4T SAE
5W/30 to the existing lineup of two full
synthetic four-stroke motor oils,
RACING PRO 4T SAE 0W/40 and SAE
15W/50. The new oil was developed
especially for off-road racing by the
MOTOREX Racing Lab in collaboration
with KTM. RACING PRO 4T SAE
5W/30’s special formula and additives
are the perfect answer to the
conflicting goals of withstanding the
extreme demands on wet clutches
in motocross and
providing lubrication
for very high-RPM
one-cylinder fourstroke
engines. The
result is maximum
racing performance
combined with optimum
clutch action.
4
BIOGARD CHAIN OILS REFORMULATED
OVER 25,000 DIESEL ENGINES EVERY DAY
P.S.A. Peugeot Citroën produces over
25,000 diesel engines a day at its
Douvrin and Trémery engine plants.
The world’s largest diesel engine
producer’s customers are not only
French automakers; BMW, Ford,
Volvo and others also have their engines
built here.
Countless machining centers grind,
mill, turn and bore the various aluminum
and cast iron engine components
in three shifts. MOTOREX
COOL-X spindle coolant is used in
the spindles with great success:
there have been no spindle downtimes
due to cooling problems since
the switch to COOL-X. And COOL-X
can stay in the system for two full
The trend toward rapidly biodegradable chainsaw lubricants is advancing
steadily. MOTOREX’s BIOGARD and BIOGARD PLUS products are the result of
over ten years’ experience with chainsaw oils based on renewable raw
materials. The latest formula further improves the speed (10-day window)
and biodegradability within 28 days (based on OECD 301 B), to 87% for
BIOGARD PLUS and no less than 99% for BIOGARD!
The all-important wear protection properties, excellent adhesion and
anticorrosive and viscosity-temperature characteristics are also enhanced,
guaranteeing ideal lubrication for all chainsaws all the year round.
years. When the time comes, a
trained maintenance team (photo)
changes the fluids during the summer
break.

KTM 350 SX-F WITH A
MOTOREX EXTRA
“Efficient, maximum transmissible power from smaller engine volumes,
tailored to the rider’s needs” was the vision guiding KTM and Stefan Everts
(ten-time MX world champion and KTM Race Director) in developing the
KTM 350 SX-F. With a completely new four-stroke fuel injection gasoline
engine, new body work and a chassis with a linkage-equipped rear suspension
system, KTM is revolutionizing the MX-1 class, capturing the world
championship in its first season.
Like all KTMs, the new SX-F is filled with MOTOREX motor oil, in this case with
race-tested CROSS POWER 4T SAE 10W/60. And now KTM and MOTOREX are
giving customers one more reason to smile when they take delivery of their
new 350 SX-F, by including a free two liters of the pioneering fully synthetic
motor oil. That way buyers can start their first ride right. www.ktm.com
Photo: KTM
SUCCESS FOR SWISSCOOL TRESOR
A world first from MOTOREX has
met with great interest in the press
and among many leading metal
processing companies. SWISSCOOL
TRESOR coolant-lubricant concentrate
now uses new technology
which protects the emulsion effectively
against bacteria. The product
is free from problematic substances
and there is no need to add any
“chemical bludgeons” in the form of
bactericides, fungicides, boron, amines,
etc. SWISSCOOL TRESOR also
guarantees top cutting performance
and the highest human and
environmental safety characteristics.
Together these properties
MOTOREX MAGAZINE I DECEMBER 2010
provide unparalleled cost-effectiveness.
The powerful advantages
of the new MOTOREX technology
and the strong positive response in
the press have persuaded many
renowned companies to progressively
switch to SWISSCOOL TRESOR
in their machining centers.
FOCUS FE SAE 5W/30
COMBINES FUEL
ECONOMY AND LOW SAPS
This modern LowSAPS motor oil
meets the stringent requirements for
the latest generation of trucks (Euro
4 and 5) with de-NOx catalytic converters,
diesel particulate filters and
SCR (selective catalytic reduction).
With its special FM (friction modifier)
additives, FOCUS FE at viscosity
5W/30 also yields up to 3% fuel
savings compared to conventional
SAE 15W/40 motor oils. It also meets
leading truck manufacturers’ stringent
requirements with regard to
extended oil change intervals, wear
protection, engine cleanliness, etc.
Always observe manufacturers’
recommendations. Contact your
MOTOREX partner for more
information.
CLEAN WINDSHIELD
WITHOUT VOCS
Available immediately, MOTOREX
offers a VOC-free all-year windshield
wiper fluid concentrate and a VOCfree
winter ready-mix fluid (–20 °C).
An ultramodern formula containing
a wide range of highly effective
cleaning components keeps the
solvent concentration low. Another
major advantage is easier storage
since the new generation of wiper
fluids is non-flammable. MOTOREX
VOC-free wiper fluids keep windshields
crystal-clear and, at the right
concentration, prevent spray systems
from freezing in low temperatures.
The all-year concentrate can be mixed
with water at any ratio (a 50:50 winter
mix offers antifreeze protection
down to –20 °C).
5
Photo: Mercedes-Benz

TOPIC
6
Photos: Prinoth AG
Snowcats with diesel particulate filters need a modern LowSAPS motor oil to run at their best.
THE RIGHT MOTOR OIL
FOR LOWER EMISSIONS
Future emissions limits will also apply to diesel engines in utility vehicles
like snowcats. Technical innovations in engine construction are also
redefining the boundaries for motor oils.
Ever-stricter European emission standards are obliging
engine and vehicle manufacturers to think years ahead,
and technology is advancing steadily. To meet EU
exhaust gas levels III B (in effect from 2011) and IV (from
2014), engine manufacturers are turning to
• Exhaust gas treatment and recirculation systems
• Electronically controlled high-pressure common
rail injection systems
• Improved surfaces and stricter manufacturing
tolerances
• High-lubricity technology and state-of-the-art
materials
• Special valve seals and piston rings
• Innovative compound turbocharger systems
• Improved combustion chambers for more
complete combustion
• More efficient engine cooling systems
and much more.
A DELICATE BALANCE
In a joint declaration of intent with the DETEC (Swiss
Federal Department of Environment, Transport, Energy
and Communications), the Swiss Cableway Association
has recommended purchasing only snowcats with
diesel particulate filters (DPFs) since the start of 2010.
Keeping the latest generation of engines with innovative
exhaust gas treatment systems running economically
and smoothly requires not only low-sulfur (below
10 ppm) diesel fuel, but also a low-SAPS motor oil (with
very low sulfate ash, phosphorus and sulfur content).
Why is that, exactly?
To keep the diesel particulate filter functioning smoothly
during snowcat operation, the exhaust gas temperature
must remain above 250 °C. Exhaust gas pressure must
not exceed about 200 mbar, since higher pressures can
reduce performance and raise the engine temperature.
Besides the fuel’s sulfur content and completeness of

The latest diesel engines wouldn’t run without electronic
assistants. Future engine management systems will use
even more electronics.
combustion, formation of sulfate ash in the exhaust
gases is also affected by contamination from ash-containing
additives in earlier motor oils. In response, MOTOREX
invested in the development of its FOCUS low-SAPS
motor oils several years ago.
LOW-ASH ADDITIVES AND SULFUR-FREE
BASE STOCKS
High-performance FOCUS QTM SAE 10W/40 motor oil is
built on quality base fluids and features MOTOREX’s integrated
low-SAPS technology. The combination of an innovative
additive package with low-ash ingredients and a
specially produced sulfur-free base stock makes it ideal
for vehicles equipped with exhaust gas treatment
systems such as de-NOx catalytic converters, diesel particulate
filters (DPFs) or selective catalytic reduction (SCR)
systems. It is ahead of its time in its compliance with the
strict ACEA E9/E6 standards, clearing the way for practical
implementation of the latest technologies.
This makes MOTOREX FOCUS QTM ideal for use in modern
snowcats, with the following compelling benefits:
• Already meets ACEA E9/E6 standards
• Ideal for the latest engines with exhaust gas
treatment systems
MOTOREX MAGAZINE I DECEMBER 2010
Exhaust gas treatment systems require a LowSAPS motor oil to function
at full efficiency. FOCUS QTM meets these requirements as well as the
ACEA E9/E6 standards.
• Allows filter systems to function at optimum
efficiency and durability
• Provides outstanding protection against wear
• Enables extended service intervals
(follow manufacturer recommendations!)
Your MOTOREX partner will be glad to answer any
questions you may have on choosing the right motor oil
for your vehicle fleet.•
SPECIFICATIONS
ACEA E9, E6
API CI-4, CH-4, CG-4
MB approval 228.51
MAN M 3477, MAN 3271-1
VOLVO VDS 3, CNG
DAF E6
Renault RXD, RGD
Deutz DQC III-05
Global DHD-1, MTU 3.1
CAT ECF-1-a
Deutz DQC III-05
7

HYDRAULIC OIL
Perfectly conditioned ski trails depend
on 100 liters of hydraulic fluid
flowing through a complex system.
Willi Tremp of BEST AG tells us about
his experience with MOTOREX’s
OEKOSYNT HEES biofluid.
8
GREEN ON
WHITE SKI TRAILS
The annual process of preparing winter sport areas demands a great
deal of work from snowcats and their drivers alike. The demands placed
on lubricants are equally extreme. As a rapidly biodegradable hydraulic
fluid, MOTOREX OEKOSYNT HEES also sets new performance standards.
Speaking for the many snowcat operators who use
OEKOSYNT HEES, Willi Tremp, operating technician for
Bergbahnen Engadin/St. Moritz AG (BEST AG) tells us
about his experience with MOTOREX’s pioneering
biofluid.
“Extended change intervals and
high environmental compatibility
are important factors for us”
MOTOREX magazine: “Your region uses only rapidly
bio degradable hydraulic oils. Why is that?”
Willi Tremp: “As a region that depends on tourism, unspoiled
nature is our most important asset. That’s why,
in keeping with our corporate vision, we use environmentally
friendly technologies wherever possible. That
includes lubricants and other consumables.”
MOTOREX magazine: “Has OEKOSYNT HEES made it
possible to extend fluid change intervals compared to
the mineral-based hydraulic oil you used to use?”
Willi Tremp: “Yes, significantly. In our region we operate
24 snowcats. Kässbohrer, for example, prescribes a fluid
change interval of 1,200 hours for mineral hydraulic oil.
With OEKOSYNT HEES, we’ve been operating certain
machines for 4,200 hours already without changing the
fluid! That means that machines can go an entire season
without an oil change even with extremely heavy use.”
MOTOREX magazine: “What are your maintenance
routines like?”
Willi Tremp: “We stick to the manufacturers’ recommendations.
Change the filter and top up
the fluid where needed. We perform a visual
inspection of all hoses at regular intervals.
We also send samples to the MOTOREX
lab for analysis when necessary. The
results tell us if it’s time to change
the fluid or microfilter it.”

Willi Tremp regularly takes hydraulic
fluid samples and sends them to
MOTOREX for analysis.
MOTOREX magazine: “That means you use MOTOREX’s
customer and laboratory services?”
Willi Tremp: “Yes. To me that’s an important part of the
product and one that provides security for us as users.”
MOTOREX magazine: “How long does it take to flush
the hydraulic system and change the oil in a snowcat?”
Willi Tremp: “By yourself it can take a day or a day and a
half. Nowadays you can order snowcats with factoryfilled
biodegradable HEES hydraulic oil. That’s what our
region does.”
MOTOREX magazine: “What product benefits were
foremost in your choice of OEKOSYNT HEES?”
Willi Tremp: “The product is 100% in line with our vision.
So far we’ve had nothing but good results with it. It’s
also quite a bit more economical than what we were
using before. We work three or four times longer with
one and the same fluid fill.”
MOTOREX magazine: “In your view, what is the main
benefit for St. Moritz as a ski area?”
Willi Tremp: “That’s got to be how economical it is
thanks to the extended service intervals, and naturally
the assurance of working with a biofluid that’s absolutely
safe for the environment. This is also something our
guests appreciate a great deal and it’s an important
image factor.”
Do you have questions about hydraulic oil in snowcats?
Just contact your MOTOREX partner for technical
advice. •
MOTOREX MAGAZINE I DECEMBER 2010
Over 1,000 snowcats are in use for conditioning ski trails in Switzerland. In the Engadin they are
exclusively filled with HEES hydraulic fluids.
OEKOSYNT HEES PASSES SAUER-DANFOSS TEST
Official approvals and successful testing by the leading hydraulic component
supplier further underscore the superiority of MOTOREX OEKOSYNT
HEES. The biofluid based on liquid saturated esters meets
• DIN ISO 15380 environmental and technical standards for HEES fluids
• VDMA 24570 non-ferrous metal compatibility (Linde test)
• DIN 51524 HLP and HLVP performance levels
• the Sauer-Danfoss H1P078 and H1B110 tests
• and holds Bosch Rexroth A4VSO125, KAISER AG Fahrzeugbau,
Prinoth AG and other manufacturers’ approvals.
Photo: Sauer-Danfoss
High-performance hydraulic pump on test equipment at Sauer-Danfoss.
9
Photos: Bergbahnen Engadin/St. Moritz AG

REPORT
10
The SWISSAUTO POLO REX engine compartment with electric motor, power electronics and range extender –
this Swiss technology is drawing lively interest from auto manufacturers.
SWISS HIGH TECH FOR
the automotive world
of tomorrow
Switzerland, land of mountains, watches, chocolates… and cars! Automobiles
may not be mass-produced here, but few if any new cars in
the world roll off the assembly line these days without parts from Swiss
suppliers. And highly innovative Swiss companies are taking a leading
role in shaping the future of the industry as technology suppliers.
Over 300 companies in Switzerland, mostly small and
medium-sized enterprises (SMEs), are involved in production
for the international automotive industry. They
“New technologies in the automotive industry”
manufacture parts out of various metals and plastics as
well as electronic components in large series. But Swiss
companies also supply production equipment as well as
molds and tools for automotive manufacturing.
AUTOMAKERS AS PRODUCTION PROS
Automakers purchase most of the 20,000 or so parts that
go into a typical car from suppliers, manufacturing only
a few key components such as the engine and body
themselves. Practically everything else is purchased on
the global market, enabling the automakers to focus on
optimizing production costs. Nowadays all leading manufacturers
offer outstanding quality at competitive prices.
Total production volume in 2010 is again expected to
reach some 70 million vehicles.

The battery pack is installed space-efficiently beneath
the trunk cover. No trunk room is sacrificed.
KNOWLEDGE CHANGES HANDS
Research and development continue to play a very special
role in auto manufacturing. Without the requisite technologies,
automakers can’t set new trends or keep up
with the evolving market. For this reason, innovation and
know-how in the following areas is often acquired from
outside the company:
• Alternative propulsion systems
(hybrid, electric, fuel cell, etc.)
• Smaller internal combustion engines optimized
for fuel efficiency and performance
• General reduction in weight and rolling resistance
• Aerodynamic optimization
• Emission reduction concepts with the ultimate
goal of “zero emissions”
In their efforts to integrate as many of the components
that embody the hottest new trends into production
vehicles at the lowest cost, many automakers turn to
engineering studios in Switzerland.
SWISSAUTO COMBINES TECHNOLOGIES
For years, SWISSAUTO WENKO AG in Burgdorf has been
seen by many international automakers as one of the
MOTOREX MAGAZINE I DECEMBER 2010
Photo: Swissauto Wenko AG
Successful research and development depends not only on brilliant ideas,
but also on quality resources and specialized staff.
leading engineering studios for combustion engines and
turbochargers. The company’s technological back-
ground was developed through many years of working
with reduced-displacement and highly turbocharged
gasoline engines and involvement in various aspects of
auto and motorcycle racing. So it is no surprise that
SWISSAUTO has repeatedly supplied new technologies
to major corporations in the automotive industry, many
of which are now used in series production.
“The team has gathered a number of innovations
into one winning technology package!”
In the SWISSAUTO POLO REX (REX = range extender), the
team from Burgdorf has gathered a number of innovations
into one winning technology package. This
“electrified” vehicle based on a VW Polo is equipped
with a Brusa hybrid synchronous electric motor deli vering
85 kW (115 hp) of output and 220 Nm of torque.
The REX is powered by electricity in all operating
modes. A one-cylinder, 0.3-liter four-stroke engine developed
by SWISSAUTO, along with energy recovered
from the braking system, charges the lithium ion polymer
battery (14 kWh).
11

REPORT CONTINUED
The one-cylinder, 0.3-liter internal
combustion engine supplies 26kW
of power and is directly connected to
the 30-kW Brusa generator.
12
The crankshaft (left) and camshafts
of the 300-cc range extender
engine are equipped with lowfriction
roller bearings.
REX PROVIDES 800 KM RANGE
The range extender directly addresses a weakness of
electric vehicles. Although the battery’s 100 km range is
enough to meet the average driver’s daily mobility
needs on electric power alone, the vehicle must be capable
of longer trips as well. When necessary, the SWISS-
AUTO POLO REX uses the range extender to generate
electric power for recharging its own batteries.
“The SWISSAUTO team worked closely with the
specialists at MOTOREX to minimize engine friction”
The newly designed one-cylinder gasoline engine was
engineered for maximum fuel efficiency right from the
outset. This was primarily achieved by using roller
bearings rather than slide bearings throughout and
employing a special dry sump lubrication system to
reduce friction. The SWISSAUTO team worked closely
with the lubrication technology specialists at MOTO-
REX to minimize engine friction.
The SWISSAUTO engine consumes only the equivalent of
about three liters of fuel per 100 km, fully meeting SWISS-
AUTO’s goal of charging the batteries with a small and
economical 26 kW (35 hp) range extender. This achievement
is proof that the combustion engines used in today’s
mass-market hybrid vehicles are still too large. The REX’s
quick-filling 27-liter fuel tank gives it a total range of
Photos: Swissauto Wenko AG
Turbocharged reduced-displacement gasoline engines also
have great potential for the future. The photo shows a
c ombustion chamber test bench built by SWISSAUTO in
collaboration with AVL.
about 800 km and the car can accelerate its 1,245 kilograms
from zero to 100 kph in just 8.5 seconds.
HIGH EFFICIENCY, LOW EMISSIONS
The extremely compact fuel injection intake manifold
engine boasts an efficiency of 37%, which is astonishingly
high for a gasoline engine. Its specific consumption
values are comparable to those of a modern direct-injection
engine. The mini-motor will also run on ethanol.
This means that, depending on the source of electricity
and fuel, the POLO REX can be operated on a completely
CO -neutral basis.
2
The REX always runs on electric power; the range extender’s
one-cylinder gasoline engine is used only to
charge the batteries. This means that the combustion
engine continuously runs within its optimum operating
range. This clever design, with no constantly changing
loads, yields outstanding engine efficiency. The combustion
engine’s catalytic converter is also pre-heated after
the electric motor starts. Once the converter has reached
operating temperature, combustion can start and continue
with low emissions from the first turn of the
crankshaft. This feat of engineering lowers pollution
emissions by as much as 80% compared to a conventional
modern gasoline-powered passenger car!
SWISS HIGH TECH IS IN DEMAND
In conventional automotive engineering, Swiss precision
is in especially high demand when it comes to safety and

Photo: BRUSA AG
BRUSA Elektronik AG supplied the high-efficiency
performance electronics for the POLO REX; testing
on the electric motor test bed.
dependability. Examples include components for highpressure
fuel injection systems (common rail systems) in
the latest generation of economical, low-emission diesel
engines, safety features such as airbag igniters and ABS
sensors, dependable locking systems, noise-muffling interior
linings and corrosion-resistant chassis.
A COMPACT BUNDLE OF INNOVATION
The SWISSAUTO POLO REX combines a number of futuristic
features. For once, the expression “high tech” is apt.
The POLO REX offers
• a full-featured, highly comfortable electric drivetrain
• sophisticated engineering
• extremely high efficiency
• low emissions
• everyday practicality
In building the POLO REX, SWISSAUTO received support
from the Swiss Federal Office for Energy and worked
closely with Brusa Elektronik AG (www.brusa.biz). The
Sennwald-based electronics company supplied the lithium
polymer battery (135 kg), the electric motor and the
power electronics. The POLO REX was converted, tuned
and tested by SWISSAUTO (www.swissauto.com).
Remarkable how Swiss inventors and manufacturers,
after the many automotive achievements of the past
hundred years, are now playing a pioneering role in
alternative mobility technologies. •
MOTOREX MAGAZINE I DECEMBER 2010
Fredy Barth took the SWISSAUTO POLO REX for a test run for MOTOREX
magazine and clearly enjoyed himself.
HOW THE POLO REX DRIVES
Fredy Barth, racer (WTCC series, SEAT SWISS RACING Team)
and test driver, drove the SWISSAUTO POLO REX exclusively for
MOTOREX magazine.
Fredy Barth: “It looks almost like a normal VW Polo, aside from the
wheel covers, modified front end and rear spoiler. The SWISSAUTO
POLO’s zippy performance compared to other alternative propulsion
systems is an absolute highlight given its range. In D gear, the electric
motor’s 50kW output sends it gliding along effortlessly. In the sporty S
position, the front wheels receive a full 85 kW (115 hp) from standstill.
The perfectly tuned power electronics function without jolts and in just
the right dosage.
In stop-start mode, the REX range extender can be activated manually
or electronically. The driver would have to listen very closely to hear
any difference in noise levels from having the REX on or off. The
SWISSAUTO one-cylinder engine is perfectly well-behaved; it produces
absolutely no vibrations and runs smoothly even at a full 7,000-rpm
load. When the range extender is on, the combustion engine switches
off below 25 kph and back on at around 50 kph. Power is transmitted
by a one-gear continuously variable transmission. Top speed is limited
to about 130 kph for optimum energy efficiency. But when braking,
you first have to get used to the response and feedback from the
brake pedal. The energy recovery system in the brakes gives them a
significantly different feel from conventional brakes.
The fine-tuning of the vehicle and the successful redesign of the drive
train make SWISSAUTO’s POLO REX not only extremely good for the
environment, but also a lot of fun to drive!”
13

INSIDE
14
The Atom Emissions Spectrometer (AES) rapidly and precisely identifies trace elements such as wear components
(metals) and additives.
RESEARCH, DEVELOPMENT AND ANALYSIS
FOR OUR CUSTOMERS
MOTOREX is continually expanding its laboratory capacity. Additional
staff and state-of-the-art equipment guarantee the MOTOREX lab’s
capacity. For our customers, this means cutting-edge products, guaranteed
quality and fast analytical services.
As an independent lubricant company, MOTOREX has
a tradition of ongoing investment in research and
development and has made R&D a key factor in its
success. The laboratory in Langenthal, with its expert
staff and innovative infrastructure, exemplifies this
commitment.
“New analytical methods”
AUTONOMOUS AND FORWARD-LOOKING
MOTOREX is currently capable of conducting over 95%
of analysis and development processes in its own laboratory.
This is especially important for technologies that
have not yet been patented. Tribology experts are con-
stantly inventing new analytical methods and ingenious
equipment, often developed in-house. The lab also
has close relationships with technical institutes for
farther-ranging investigations and test bench trials.
MOTOREX performs some 120 types of analysis and
investigation in its own facilities (see chart on page 15).
RAPID ANALYSIS
The emphasis in the MOTOREX labs is not only on pure
science, but also on practical results. Countless customer
samples are analyzed every day. The objective is to
conduct the analyses as rapidly, but also as precisely as
possible. In recent months, many analytical methods
have been automated. This lets customers know in a

timely fashion whether a lubricant needs changing or if
it’s safe to keep using it.
A TYPICAL ANALYSIS
The following scenario gives a clear picture of the lab’s
day-to-day work in analysis of raw materials, finished
products and customer samples from actual use. This
specific analysis can be used to determine the condition
of the machine and the medium, which in turn
makes it possible to predict the remaining service life of
the fluid.
For hydraulic fluids, the relevant examination methods
are combined in a set of tests. In most cases a representative
view of the condition of the lubricant is not pro -
vid ed by a single test value, but rather a number of test
results and the way they are interpreted.
HYDRAULIC FLUID ANALYSIS
1. Visual inspection of incoming sample: The specialist can
often recognize certain problems by sight (color, water,
wear) or smell (burnt).
2. Viscosity at 40 °C/100 °C and the viscosity index calculated
from these figures: This is where test values are compared
with specification tolerances. This phase provides
information on shear stability, lubricity, etc.
3. Infrared readings: By comparing with reference samples,
IR spectra can be used to identify even minor variances
from fresh oil.
4. Aging stability by measuring total acid number: The TAN
increases as oxidation products accumulate during operation
– the concentration of acidic oxidation products rises.
If the concentration exceeds a critical point, a deterioration
in the lubricant’s tribological properties may result.
5. Measurement of elemental content: This measurement
enables conclusions about changes in concentrations of additives
and wear elements such as chromium, molybdenum,
copper, etc. Modern alloys and composite materials have
made additional elements such as silicon and tungsten a
focus of testing.
6. Measurement of water content: Water content is particularly
critical in hydraulic fluids, since water evaporation
can lead to failure of hydraulic systems. Moisture content
is measured using the Karl Fischer titrometer (DIN 51777).
7. Determining cleanliness class (ISO 4406): Hydraulic
fluid cleanliness classes are growing in importance as
microfiltration systems are becoming more widespread in
modern hydraulic equipment. Particles should also be
prevented from circulating within the hydraulic system to
avoid a large increase in wear.
The MOTOREX laboratory team and the services it
performs will always be a key success factor in compelling
products and well-received services from
MOTOREX. •
MOTOREX MAGAZINE I DECEMBER 2010
Every day the MOTOREX lab receives a large number of customer samples
for quick, high-precision analysis.
Rapid, precise analysis of incoming raw materials and production batches saves
time and enhances productivity.
Equipment Analysis
Viscosimeter Dynamically/kinematically determining viscosity
IR spectrum Determining identity and divergence from
(infrared spectroscopy) reference values, lubricant composition analysis
Cold cranking simulator Low temperature resistance to starting
Karl Fischer titrometer Water content of lubricants
pH titration Measurement of acidic components,
determining changes in concentration of
acidic compounds, for example due to
oxidation processes. Determining alkali
reserves of oil formulations
RFA/spectroscopy Determining elemental content of oils
Pour point test device Automated low-temperature flow
characteristics of oils
NOACK test device Evaporation loss of base oils and
final formulations
Flame point measuring Fuel contamination, quality characteristics/
device deviations
BOSCH pump Shear stability, viscosity loss during
lubricant use
Particulate measuring Particulate contamination through wear
device and foreign matter
Filterability measurement Determining filterability
device
See also Tribology A–Z at www.motorex.com for explanations of
technical terms.
15

EXPORT
16
For its 40th anniversary in 2008, Storm Motor Oy moved to a new headquarter with central warehouse and an
impressive retail shop.
STORM MOTOR OY:
MOTOREX IN FINLAND
Turku-based Storm Motor Oy has been an importer and distributor of the
MOTOREX MOTO LINE in Finland for many years. The family business is
popular among dealers and consumers alike – a balancing act that is the
sign of true professionals.
Storm Motor was founded in 1969 by current CEO Jyrki
Storm. A top-level European Motocross Championships
racer at the time (including a 5th place in the 250 cc
Motocross World Championship in 1967), Mr. Storm
used his international connections to start an import
business for motorcycle parts and accessories. During
the following years the business would grow to reach
motorcyclists throughout Finland through mail-order
catalogs and a growing dealer network. Starting with
one retail store at its headquarters location, Storm
gradually added new outlets over the years. A second
store was opened in Helsinki in 1978, and today there
are company-owned Storm Motor shops throughout
Finland.
QUALITY AND DEPENDABILITY PAY OFF
Storm Motor built a reputation as a reliable partner in
the motorcycle market in record time, serving customers
with a broad assortment of parts, accessories and equipment
ranging from top brands to affordable alternatives.
Although the company operates its own stores
and maintains an active catalog sales operation, it also
serves a network of dealers who have rewarded Storm’s
commitment to quality and high dependability with
exceptional loyalty.
THE MAGIC NUMBER 5
Storm Motor has opened five company-owned retail
outlets to date, at its headquarters in Turku, in the

Finnish capital of Helsinki, in Tampere in the country’s
interior, in Oulu in the north, and the newest in Lahti
in the Finnish Lake District. Together these stores cover
an area of over 5,000 square meters, supplied from a
5,500-square-meter central warehouse in Turku.
Storm’s retail stores serve motorcyclists directly and
act as a fast delivery point and large-order depot for
local dealers and repair shops. In its business-to-business
operations, Storm Motor’s satisfied clientele
comprises 500 dealers. All customers can also use
Storm’s state-of-the-art website to purchase products
and exchange information.
TOP BRANDS LIKE MOTOREX
Storm represents the top brands in the industry – including
MOTOREX, Nolan, EBC and Michelin – and is
committed to exceptional quality. In 2009 the company
recorded sales of EUR 7 million. Since the motorcycle
market appears to have reached a saturation point,
Storm is constantly working on new products and
ways of doing business at the company’s headquarters
in Turku. The company places a special emphasis on
caring for existing customers to their complete satisfaction.
Storm markets and advertises extensively and
is one of the leading advertisers in Finnish motorcycling
publications.
Within the company, MOTOREX is frequently cited as
an outstanding example of innovation and quality.
Partnering with KTM has proven to be a great way to
raise the MOTOREX brand’s international profile, creating
a strong association with success in motor sports.
Motor racing has long been among the most popular
sports in Finland!
READY FOR THE FUTURE
Storm Motor’s management team and product managers
keep their eyes and ears open and are constantly
thinking of the future. In the highly contested parts and
accessories market, discovering new products and
developing innovative services quickly and at the right
time are key success factors. Storm is continually improving
logistics and delivery services and has significantly
cut both costs and average delivery times. This approach
keeps the company open to new opportunities and ready
to face any challenge. The company’s 34 employees
throughout Finland have made Storm Motor a name
to be spoken with pride. •
www.stormmotor.fi
MOTOREX MAGAZINE I DECEMBER 2010
A strong team (l. to r.): Sirkka Storm (Vice President) and Jyrki Storm
(founder and CEO) in front of their “favorite products” from Switzerland.
The spacious sales floors at each Storm retail outlet provide the ideal surroundings
for a perfect shopping experience.
Active promotion is a must in Finland too – Storm Motor delivers up
to 75,000 catalogs directly to consumers each year.
17

INDUSTRY
PRECISION FORCEPS FOR
ENDOSCOPIC SURGERY
For many years Bacher Medizintechnik of Tuttlingen, Germany has specialized in
the manufacture of alligator and biopsy forceps for use in endoscopes. The company
relies on Swiss technology to produce these mechanical masterpieces. All turned
parts are manufactured on a Tornos Micro 7, and high-performance MOTOREX ORTHO
NF-X cutting oil is used for all machining processes.
18
Alligator and biopsy forceps are available in diameters from 1 to 5mm and in flexible or rigid versions in lengths up to 200cm.
INNOVATION IN MEDICAL DEVICE PRODUCTION:
In the German-speaking world, Tuttlingen is regarded as
a major center for medical engineering, a status reflected
in its leading role in manufacturing. Continuous
improve ment in production processes is as much of a
given in this sector as ever-more specialized materials
and tools. So it was no surprise when Bacher turned to
the lubrication specialists at MOTOREX in its search for
ways to optimize its production processes.
ADVANTAGES OF MULTIPURPOSE CUTTING FLUID
Certain production steps have always had to be performed
on machines filled with the “right sort” of cutting
oil, but lately the company had been looking for a cutting
fluid that could be used anywhere. Of course, even
in a universal fluid, any compromise on performance
was out of the question. MOTOREX’s recommendation
to switch to its ground-breaking, high-performance
ORTHO NF-X cutting oil offered several advantages at
once for the user: All machining processes, including
turning, drilling, milling and threading, could now be
carried out with one and the same fluid. And thanks to
the fluid’s integrated Vmax technology, both production
quantities and Ra (surface roughness) values improved.
TOOLS IN LIQUID FORM
Machining the materials used in medical engineering
requires extremely high cooling, lubrication and rinsing
performance from the medium. Nowadays, rinsing

The forceps jaws are connected by joints with a pull mechanism.
Here, a wire is laser-welded to the mechanism
under optical magnification.
pressures of up to 120 bar are not uncommon, and out-
standing high-pressure characteristics are a must. To
withstand these extreme pressures, the lubricating
film must exhibit extraordinary temperature and pressure
stability. SWISSCUT ORTHO NF-X meets all these
requirements with aplomb. Through ongoing development
of this high-performance cutting oil and the
MOTOREX Vmax technology, MOTOREX has made a
significant contribution to innovation in the industrial
manufacture of medical device components. The fluid
is also free of chlorine and heavy metals and easily
cleaned away.
It is generally understood in component manufacturing
that the whole process is only as efficient as the weakest
link in the chain. Accordingly, the four success factors of
machine, tool, machining fluid and operator are all
equally important. A company has little to gain by
invest ing in the latest generation of machinery if it
skimps on staff training or uses an outdated cutting oil.
CUTTING COSTS – PROTECTING
THE ENVIRONMENT
The data from the machine reports show that switching
to innovative MOTOREX cutting oil has paid off in terms
of output, tool service life and quality. The current generation
of ORTHO products is also risk-free for human
health and the environment and thus helps create better
MOTOREX MAGAZINE I DECEMBER 2010
The results of milling with MOTOREX ORTHO NF-X can be seen in the arms of
the forceps – and in the tool service life of the HSS milling cutter.
As important as a high-performance machining center: the choice of machining
fluid has a significant impact on the production process and costs.
working conditions. This not only has a positive effect on
the atmosphere in the workplace, but also helps reduce
maintenance and disposal costs.•
“THE TECHNOLOGY HAS MADE A BELIEVER OUT OF ME”
“MOTOREX ORTHO NF-X really surprised me! I didn’t
expect it to have much impact on production results,
but this innovative cutting oil began showing its full
performance potential with the very first series of
tests. Here are just a few of the things I’ve found using
ORTHO NF-X:
• Allows machining of all materials
Mate Bekavac
• Guarantees top performance in all processes,
such as drilling, turning, milling, spinning, etc.
• Reaches working temperature quickly and provides outstanding
cooling characteristics
• Removes swarf without foaming at pressures up to 120 bar
• Provides ideal lubrication
• Helps to significantly increase tool life
• Easily removed from the workpiece
• Free of undesirable critical substances
I’m glad we’ve switched to the Swiss cutting oil. It makes our day-to-day
production work here noticeably easier.”
Mate Bekavac, machine operator
Bacher Medizintechnik, Tuttlingen, Germany
www.bacher-medizintechnik.de
19

PRACTICE
20
To keep equipment operating with low wear, automatic lubrication systems have to be refilled regularly with the right grease.
TECHNICAL GREASE 219
KEEPS CONSTRUCTION
EQUIPMENT FIT
The capabilities of the ever-more powerful construction equipment used
in earth-moving work are astonishing. And the loads on greaselubricated
components are just as imposing. That’s why MOTOREX
developed heavy-duty lithium grease 219.
Anyone who faces the extremely harsh conditions in
which heavy earth-moving and construction equipment
operates every day knows all about constant
heavy loads. Wheel loaders, excavators, cranes, conveyor
belts, shredders, mills, crushers and screening units
are all expected to work perfectly in all temperatures
and weather conditions. Keeping them running
smoothly requires skilled operators and the right heavyduty
grease to protect all lubrication points reliably.
HANDY SOLID LUBRICANTS
The new heavy-duty GREASE 219 is a semi-synthetic lithium
complex grease. The formula contains lithium (Li),
which together with other solid lubricants including
PTFE (polytetrafluorethylene/Teflon®) provides a number
of beneficial properties in the innovative new GREASE
219 product. The EP (extreme pressure) grease has good
adhesive properties and provides effective protection
against wear and corrosion. A special additives package

Regular application of lubricant to lubrication points that
are not connected to an automatic lubrication system
prevents unpleasant surprises.
with a high solid lubricant content gives the technical
grease the following benefits:
• Extreme pressure resistance
(four-ball tester welding load >6000)
• Outstanding emergency running properties
• Good protection against corrosion and oxidation
• Wide range of operating temperatures
• Good water resistance
• High fulling stability
A WIDE RANGE OF APPLICATIONS
GREASE 219 is suitable for lubricating heavily loaded
roller and slide bearings as well as sprocket gears and any
lubrication points that require high pressure resistance.
It is ideal for use in automatic lubrication systems. The
grease can also be applied manually with a grease gun.
With an operating temperature range of –20 to +150 °C
(or even +200 °C for short periods), this grease can withstand
almost any climatic challenge.
FOR LIEBHERR AND OTHERS
The new MOTOREX GREASE 219 can be used in Liebherr
machines in place of the manufacturer’s recommended
MOTOREX MAGAZINE I DECEMBER 2010
GREASE 219 is available in 400g cartridges and 17kg containers
and can be easily loaded into mobile greasing systems.
The four-ball apparatus is used to test the lubricant’s
pressure resistance up to the point at which the balls
weld together.
grease 9900. The new product also meets the specifica-
tions of other major construction equipment and vehicle
manufacturers such as Caterpillar, Komatsu, Akerman-
Volvo, O&K, Volvo and Scania. GREASE 219 is an NLGI
Class 2 product and meets the strict KPF 2 P-20 specifications
under DIN 51502.
“This grease can withstand almost
any climatic challenge”
DETERMINING WELDING LOAD
Welding load is tested using a four-ball extreme pressure
(EP) testing device. The grease is tested in a four-ball system
consisting of one rotating ball in contact with three identical
stationary balls. Test loads are gradually increased until
the four-ball system welds together (see photo above).
Torque or friction torque can also be measured. At the end
of the test, the weld point of the lubricant is calculated.
MOTOREX’s new GREASE 219 has added a new heavyduty
option to the company’s range of technical greases. •
21

BOX
DID YOU KNOW THAT KWC FAUCETS ARE PRODUCED WITH MOTOREX?
OTTOREX
22
Photo: KWC AG
COOL IDEAS
Since 2007, a team of specialists from Gasser Felstechnik
AG has been regularly traveling to Maarmorilik in
Greenland, where the northernmost passenger cableway
in the world is being built. The construction site of
the planned Black Angel zinc mine is located some
400 km north of the polar circle. It is just about
access ible by sea from June to October; for the rest of
the year the ice-choked fjords are impassable.
COMPRESSOR OIL TESTED
ABOVE POLAR CIRCLE
The courageous team from Switzerland is providing
securing elements, rock fall restraining systems and
explosives work at the upper terminus, situated 600 m
above sea level on a vertical cliff face. Specially prepared
compressor oil from MOTOREX makes it possible
to work on the cliff wall even in extreme below-zero
temperatures. So spectacular is this project that BBC
World has even made a film about it. •
Camp Maarmorilik with the future upper terminus of the
planned cableway (circle).
For a first impression of the construction site, visit this link:
http://www.youtube.com/watch?v=Gt_mja_uDCE
KWC AG is a leading producer of high-quality Swiss
kitchen and bath faucets. The product line ranges from
traditional, utilitarian products to highly innovative,
design-oriented fittings. The standards KWC sets for its
suppliers are correspondingly high.
For example, a number of KWC fittings are machined
by a supplier with MAGNUM UX 500 universal coolantlubricant
from MOTOREX. Turning and milling operations
with this efficient and highly economical coolantlubricant
result in flawless surfaces. Its high lubricating
effect has resulted in a 14.5 % reduction in tool down
times. More performance with lower production costs:
MOTOREX MAGNUM meets customer needs to the
maximum! • www.kwc.ch

A CUT ABOVE THE REST!
Swiss army knife
Swiss army knife in MOTOREX green and engraved with a logo.
With this small Swiss army knife you always have the right tool to
hand. Version with large blade, small blade, corkscrew, tin opener
with small screwdriver, bottle opener with screwdriver, wire stripper,
reamer and punch, ring, stainless steel toothpick, tweezers.
Article No: 450338
Officer’s knife
Everything at hand – for both small and major trips. You always have
the right tool to hand with this “Officer‘s Knife”. Large blade, small
blade, corkscrew, can opener with small screwdriver, cap lifter with
screwdriver and wire stripper, reamer, punch, key ring inox, toothpick,
tweezers.
Article No: 450630
For your order, please use the card in the center of this magazine. Please ask your MOTOREX importer about the availability,
price and delievery time of the above article. Thank you.
MOTOREX MAGAZINE I DECEMBER 2010
23

THERE ARE THOSE WHO MAKE
COMPROMISES, AND THERE ARE
THE OTHERS. HE’S ONE OF THE
OTHERS.
WHY DO YOU THINK
HE SWEARS BY US?
Peter Julen, Technical Director Zermatt Bergbahnen
Not many people have more responsibility than Peter Julen. As Technical Director of Zermatt Bergbahnen, ,
he has to ensure that ten million passengers are conveyed safely to altitudes of up to 3880 metres every y
year, a challenge that allows no compromise. Setting radically new quality standards, never settling for the e
fi rst solution that comes along, but always insisting on the best: that’s something MOTOREX also stands s
for. And why we are precisely the right partner for Zermatt Bergbahnen. Find out more about how our oils s
are helping companies from a wide range of industries meet their ambitious targets: www.motorex.comm