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A Publication of John Deere Power Systems - John Deere Industrial ...

SERVICE AND SUPPORTA Quality Cut of Customer ServiceSelect Sawmill looks to John Deere to support thesmall company’s growing international customer baseIt’s not always easy for a smallcompany of 15 employees to succeed asa player in the global marketplace, butthat’s exactly what Select Sawmill Co. ofPlantagenet, Ont., Canada, has managedto do despite its size. That’s because thecompany’s sawmills are known worldwidefor their reliability. Plus, theircustomers know they have worldwideaccess to quality service and supportthrough the John Deere dealer network,should the need arise.Select Sawmill builds modular-stylesawmills and related equipment for thesecondary, value-added lumber market,comprising of a broad spectrum of productsfrom quality hardwood flooring tohockey sticks. The custom sawmills areavailable as stationary units or can betrailer mounted, and each is independentlypowered by a John Deere diesel.The company’s largest model, the 4221,features an 86-kW (115 hp) PowerTech4045T diesel engine. This 15.2-centimeter(6 in.) double-cut band saw iscapable of processing logs that are107-centimeters (42 in.) in diameter and6 meters (22 ft.) in length. Known for itshigh productivity, the band saw, with itscomputerized set work, is capable ofchurning out 15,000 to 18,000 board feetper day with precision. The companyalso manufactures another model ofcomparable quality in a smaller size.The 3620 is powered by the 44.8-kW(60 hp) PowerTech 4024T engine andwill easily perform two-thirds the workof the larger model.Select Sawmills are particularlyattractive to smaller operations lookingfor high-quality, user-friendly band sawsto help start or expand their businesses.The company’s reputation and saleshave grown by word-of-mouth, acrossthe globe. For this reason, SelectSawmill values the customer supportthey receive from John Deere. “We have15 employees, and we don’t have themanpower to support our products on aglobal level,” says Luc Tourangeau, thecompany’s sales manager. “That’s the keyreason why we use John Deere. Theengines are reliable, but we also want thecustomer support that comes with theengine, whether it’s in Russia, Canada, orthe tropical rainforest. Having John Deerebehind us is definitely intentional. Weneed it, appreciate it, and want it.”Remote access. Tourangeau wasimpressed by the availability ofJohn Deere support during a recentvisit to the Democratic Republic of theCongo. “There I was in a very remoteregion in central Africa where therewere huts, people with bare feet, andchickens everywhere,” he recalls, “andstanding beside me was a guy representingJohn Deere engines.”Because the sawmills often work invery remote regions, equipment reliabilityis paramount. Since the company’s inception10 years ago, John Deere engineshave been the power of choice for SelectSawmill’s two band saw models. “Everysingle John Deere engine installed in thelast 10 years is still operating,” relatesTourangeau. “Some of these units arerunning with more than 15,000 hours.“I’ve been asked ‘what is the lifetimeexpectancy of the engines,’” saysTourangeau. “I tell them, ‘I’ll let youknow as soon as one fails.’”Engines: John Deere PowerTech4045T — an 86-kW (115 hp), 4-cylinder,4.5L, turbocharged diesel engine;PowerTech 4024T — a 44.8-kW(60 hp), 4-cylinder, 2.4L, turbochargeddiesel engine. Distributor: M-K PowerProducts, Mississauga, Ont.,(905) 890-5323, www.m-k.comSelect Sawmills turn logs into lumber at a remote jobsite thanks to itsmobility and independent power source. The company looks to John Deereengines to enhance product reliability and for worldwide customer support.PowerSource 5


SERVICE AND SUPPORTHTN Climbs High InGreenhouse LiftsIn the world of agriculture, the plants aren’tthe only things growing. Greenhouses arereaching heights we’ve never seen before –and so are the machines that build them.Today’s commercial greenhouses are frequently up to 13meters (43 ft.) tall – which means large frames and extensiveareas of heavy glass panes. This calls for specialized equipmentin a field which no country understands better than theNetherlands. Among the many Dutch companies offeringtailored solutions is scissor lift expert, Hoogwerker TechniekNederland (HTN), a business that prides itself on innovation.“It’s not unusual to see greenhouses as high as 16 meters(53 ft.),” says Raymond Vis, project leader at HTN. “Whilstlarger expanses of glass help boost productivity, plant growers arefaced with significant maintenance challenges. We’ve built oursuccess on identifying and responding to their changing needs –in particular, developing higher lifts with larger platforms.”It takes nearly threemonths to build ascissor lift, and notwo are identical.“There are someobvious adaptations,”explains Vis. “Forinstance, rubber tracktires for building ormaintaining greenhouseswith concrete floors, and steel track tires for greenhousedemolition. But we offer many other design optionsto match working environments, including four kinds offlexoframes to keep the frame, scissors and platform level onuneven ground – or movable frames that allow the platformto rotate. We also offer extendable platforms to keep themachines compact; tilting platforms you can drive a cartonto; stepped platforms that match the triangular shape ofa greenhouse’s ceiling…”HTN’s 3300 UURW scissor lift – stabilitycounts when you’re up in the air andsurrounded by glass.“Of course, once you start building higher lifts, you need toadapt the whole machine,” says Vis. “It’s vital to ensure 100 percentstability and sufficient strength to handle the loads involved.That implies larger frames, larger track tires and bigger engines.Our tallest scissor lifts can reach up to 26 meters (85 ft.) andraise up to 4,000 kilograms (8,818 lbs.) of materials on a hugeplatform (13 x 5.5 meters or 43 x 18 feet), which minimizes thenumber of lifts it takes to get everything up there.”Innovative design. Based in the Dutch town of Maasdijknear Hoek van Holland, HTN makes lifting machines for saleor rent. Scissor lifts for greenhouse construction are a key partof its business, and it sells some 10 to 15 per year, all built tocustomer specifications.Engines with all the right support. “The engine is anintegral part of the design,” he says. “Ideally, we locate itbehind the scissors so the platform can be in the middle,for maximum stability. And we’ve always used John Deere.We have tried others, but none quite match John Deere’sperformance. Currently, our bigger machines are equippedwith the PowerTech 4045, while the PowerTech 4024 isperfect for our smaller ones.“Our John Deere distributor, Louis Nagel, does an outstandingjob, providing engines complete with radiator andthe necessary supports, which means installation is quickand easy. They also supply any product support, informationor back-up material we need.”6 PowerSource


SERVICE AND SUPPORTShredding SolutionWhen you’re up,you’re up. Hugeplatforms meanyou can takeeverything youneed in one go.Leading the leaders. Since its founding in 2001,HTN has grown to employ a staff of 15. It suppliesmany of the major Dutch greenhouse specialists such asVlotzicht Bouw, JC Bom VOF, and the Herman BatistGroep, who even take its equipment with them when theywork abroad.Aiming to maintain its industry lead, HTN is currentlydeveloping two larger machines, equipped withPowerTech 4045 turbo engines. “We’re also finetuningCompact and powerful, the John DeerePowerTech 4045T is ready for action.our largest-ever machine, for which the customer specificallystipulated a John Deere engine,” says Vis. HTN has extendedthe platform to 15 meters (49 ft.) and added a crane to theframe – quite an innovation, but it won’t be the last fromthis successful and progressively-minded company.Engines: John Deere PowerTech 4045T – a 74 kW(99 hp), 4-cylinder, 4.5L, turbocharged diesel engine.Distributor: Louis Nagel B.V., Nijmegen, TheNetherlands, +31 24 371 6640; fax: +31 24 378 2270,email: edhes@nagel.nl, www.nagel.nlWhen Chinese regulations nixed powering amobile document shredder from a truck transmission,Shred-Tech turned to a John Deere engineShred-Tech Corp.,headquartered inCambridge, Ont.,builds four differentmodels of truckmountedpapershredders that aresold throughoutNorth America andEurope. Ordinarily,the shredder is drivenby a power take-offfrom the truck’stransmission.Shred-Tech recently mounted its firstJohn Deere PowerTech 5030T engineon a mobile document shredderbound for China.But in China, using an idling truck that way is prohibited,so when a Chinese company wanted to buy a Shred-TechMobile Document Destruction system (MDD) last year,Shred-Tech engineers had to find a different way to powerthe shredder. They chose a John Deere PowerTech 5030Tturbocharged diesel engine.The engine and hydraulically operated shredder aremounted and coupled together in the box of a commerciallyavailable truck that can be driven to any location where largequantities of documents have been collected for destruction.The unit has the capacity to process up to a ton of materialper hour.M-K Power Products in Mississaugua, Ont., supplied theengine. M-K Power’s Robert Champion worked withShred-Tech personnel to select the right engine for the joband run application tests on the shredder and engine inCambridge. Both components were then crated and shippedto China, where a Shred-Tech technician supervised theirinstallation in a truck purchased there.The Chinese company took delivery on its MDD lastNovember, and apparently the unit has been well received.Shred-Tech reports that secure, on-site document destructionis projected to become a high-growth industry in China overthe next decade. And Champion says M-K Power will behappy to supply all the diesel engines that are needed to helppower that growth.Engine: John Deere PowerTech 5030T — a 63-kW(84 hp), 5-cylinder, 3.0L, turbocharged diesel engine.Distributor: M-K Power Products Corp., Mississaugua, Ont.,(905) 890-5323, email: robertc@m-k.com, www.m-k.comPowerSource 7


HISTORICALGrowing Up GreenLane Recycling offers new John Deere-powered tub grindersto a budding industry of small-scale wood recyclersA peek into Lane Recycling’s crystalball reveals a strong possibility that thissmall tub grinder manufacturing businessis poised to double within the nextdecade.Perhaps it’s a conservative estimate,considering the new environmentallaws prohibiting the burning or bury ofwaste are giving the recycling industrya big nudge in its favor. And LaneRecycling has just the right productsfor smaller contractors who are nowfacing these new requirements.What the Ruckersville, Va., companyoffers are three models of tub grinderswith John Deere engines, including the2408 with a 61-centimeter (24 in.)hammer mill, the 4010 with a 102-centimeter (40 in.) hammermill, andthe higher horsepower 5212 featuring a132-centimeter (52 in.) hammermill.The company also recently added theHZV52, an operator-friendly horizontalgrinder to the equipment line. It featuresan elevated in-feed hopper and isamong the few in the industry thatmake use of swing hammers toimprove the efficiency of the grind.As his company’s business grows,CEO Tom Lane, Jr., says LaneRecycling will benefit from its affiliationwith John Deere. “We’re a small company,and our ability to service ourcustomers is important to us. We knowthat when we sell a machine, anyJohn Deere ag or construction dealercan service that engine. It’s like havingLane Recycling dealers all across theUnited States.”Convenience. Lane adds that receivinga complete engine package from BellPower also cuts down on the assemblytime, which can often strain a small andgrowing business. “When those enginescome in here, they’re ready to go onthe machine. We hook up the batteries,and they’re ready to run. It’s a worldof difference for a small company likeours. And the price is very competitive.”Lane Recycling succeeds at offeringquality grinders that are affordable forsmall to medium-scale operators to ownand operate. Adding value are the hightorqueJohn Deere engines that enhancethe grinders’ ability to perform the samework as larger, competitive tub grinders.“The engines hold up excellent, maintainingthe torque that we need so thegrinder doesn’t bog down under load,”says Lane. “The horsepower and torqueof the 116-kW (156 hp) engine on oursmaller horizontal grinder surprised me.Also, the 224-kW (300 hp) engine thatwe use on both the 4010 and 2408 hasplenty of torque. The fuel economy isreal good, and it’s a very quiet engine.We’re really impressed.”Apparently, so are Lane’s customers.“We’ve been using John Deere enginessince 1988. We have John Deere-poweredgrinders that are 15 years old andstill running today. We’re not in theengine-selling business. But put aJohn Deere engine on it, and it willsell itself.”Engines: John Deere PowerTech6068T — a 116-kW (156 hp), 6-cylinder,6.8L, turbocharged diesel engine;PowerTech 6081H — a 224-kW (300hp), 6-cylinder, 8.1L, air-to-air aftercooleddiesel engine; PowerTech 6125H— a 410-kW (550 hp), 6-cylinder, 12.5L,air-to-air aftercooled diesel engine.Distributor: Bell Power Systems, Inc.,Essex, Conn., (860) 767-7502, email:don@bellpower.com, www.bellpower.comThe Lane Recycling HZV52 horizontalgrinder is powered by the 224-kW(300-hp) PowerTech 6081H engineand features an in-feed hopper with a30-degree pitch to enhance materialflow to the swing hammers.8 PowerSource


HISTORICALStrong reliability and customer service is key to keeping the Eagle recycling plants running.Rock Crushing and Rollin’ With John DeereEagle Crusher puts the polish to a gem of a reputation earned byyears of unmatched product reliability and customer supportInterruptions in the rock crushing or screening process canbe costly. Production losses due to breakdowns can amount towell over $1,000 (U.S.) an hour if a machine stops working.Eagle Crusher of Galion, Ohio, company has long beencommitted to developing crushing and screening productsthat stand the test of time. In the mid-1990s, the Galion, Ohio,company identified and moved to premium-quality purchaseparts to further enhance the reliability of its rock crushers andscreeners. And one move was a switch to John Deere engines.“We’ve had a long relationship with John Deere, and it’snot just by accident,” explains Jeff Hillis, retired parts andmarketing manager for Eagle Crusher. “Rock crushing is anextremely difficult application because of the vibration, dirt,and dust. We’re crushing tons and tons of rock. We requirethe engines and all of the powertrain parts to stand up to thatkind of feeding, and John Deere engines have done a verygood job of standing up to that task. They’ve been reliable,and our customers seem to have very little trouble with them.”Progressive moves. Eagle Crusher’s adoption of JohnDeere engines in 1995 coincided with the company’s strongdesire to move to electronically governed engines.“Electronics made a positive impact on our plants,” he says.“The electronic engines are more reliable, more serviceable,and more fuel efficient.” He adds that diagnosing is mucheasier, too. “That may make a difference between having aserviceman onsite or making the repair yourself, reducingdowntime and expense,” he says. “Plus, the engines meet all ofthe emissions requirements without a sacrifice in horsepower,”he adds, “We like them a lot.”Today, Eagle Crusher is amid yet another transition. Afteryears of exceptional performance with Tier 2/Stage IIJohn Deere 8.1L and 12.5L engine models, Eagle Crusheris in the processing of switching to Tier 3/Stage III APowerTech Plus engines with 6.8L, 9.0L and 13.5L displacements.All three models feature advancements such asfour valves per cylinder, variable geometry turbocharger(VGT), and cooled exhaust gas re-circulation (EGR) — allwith minimal changes to engine dimensions to make thetransition to Tier 3/Stage III A go smoothly.Over the years, Hillis says he’s been impressed with theservice that Eagle Crusher and its customers receive fromJohn Deere. “Our company built its reputation on being acompany that offers unparalleled customer service, including24/7 parts service,” states Hillis. “There have been manytimes when I’ve called our distributor, and they have rushedsomething to the airport or shipped something out after hoursto a customer. Over the years, John Deere, Heartland, andSuperior have been excellent at supporting us.”Hillis recalls a time when a customer had burned up a pilotbearing in a clutch. “I called the distributor at 5 p.m. and toldthem the customer needed it in New England by 7 a.m. thenext morning. They got it together. The clutch was waiting atthe gate at 6:30 a.m. That’s the kind of service Eagle is knownfor,” says Hillis. “To find partners that are willing to go thatextra mile with us means a lot to our company.”Engines: John Deere PowerTech Plus 6068 — a 205-kW(275 hp), 6-cylinder, 6.81L diesel engine; PowerTech Plus6090 — a 242-kW (325 hp), 6-cylinder, 9.0L diesel engine;PowerTech Plus 6135 — a 317-kW (425 hp) and 373-kW(500 hp), 6-cylinder, 13.5L diesel engine. Distributor:Superior Diesel, Rhinelander, Wis., (715) 365-0500,www.sdiesel.comPowerSource 9


RELIABILITYPhoto courtesy of Kelly Heyn and Jessica SarnakThe GCS 238 refuels acontainer ship with twoJohn Deere-poweredpumps capable ofdelivering 1.2 millionliters of fuel per hour(324,000 gph).A Consistent Flow of ReliabilityGellatly & Criscione choose EPA marine-certified John Deereindustrial engines for its new fleet of ocean-certified fuel bargesLike a floating filling station, the GCS 238barge travels between major port cities on theAtlantic coast in search for fuel-thirsty passengerliners and container ships bound for transatlanticvoyages. Within the 91-meter (300 ft.),double-hulled vessel are some 6,200 cubicmeters (39,000 U.S. barrels) of fuel valued atroughly $3.3 million (U.S.). That’s a lot of fuel,and some ships will consume every bit of itbefore journeying out into the broad Atlantic.Fast, reliable, and efficient pumping is a mustto move that much fuel and to avoid steepdemurrage rates of $2,500 per hour if a ship isdelayed. With an excellent track record, theGCS 238 pumps a whopping 1.2 million litersof fuel per hour (324,000 gph). Aboard thisocean-certified barge are two Byron Jacksoncentrifugal pumps each powered by its ownJohn Deere PowerTech 6125H industrialengine. The Environmental Protection Agencyhas certified the John Deere PowerTech 12.5Lindustrial engines for use in marine auxiliarycommercial applications (see note at right).Lots of forethought. Barge owners AlexGellatly and Mario Criscione, who own andoperate Gellatly & Criscione Services Corp.out of New Jersey and New York, chose theJohn Deere engines for the new GCS 238 afterextensive research and serious consideration ofall the competitive engines on the market. “Ichecked with several other people who ranJohn Deere engines concerning reliability, andequally important, the network of dealers in theNortheast,” says Gellatly. “I received nothingbut great reviews about the engines. And loand behold, John Deere has a vast network oftechnicians in the field to service them.”Gellatly says the 317-kW (425 hp) enginesoffer an ample reserve of horsepower needed tomaintain a constant rpm, which is so crucial in10 PowerSourcekeeping the refueling process running smoothly.“We needed a 15 to 20 percent reserve shouldthere be backpressure or restriction in the line,”explains Gellatly. “We have the reserve powerso it doesn’t bog down.”Electricity. In addition to the PowerTech6125H engines, the GCS 238 is fitted with twogenerator sets powered by PowerTech 4045Tmarine engines that deliver 60-kW of continuoushorsepower. The gen-sets each take turnssupplying the electrical needs to the barge,including the crew’s living quarters, the motordrivenhydraulics, air compressor, navigationequipment, blowers, and mechanical tools.Gellatly says each gen-set, alone, provides acontinuous supply of power that’s more thanadequate to run all of the barge’s electricalfunctions nonstop throughout the year.“Every one of my employees has nothingbut great reviews on the John Deere engines,”relates Gellatly. “What we need are reliablepumps and pump engines, and John Deere fitour package perfectly. The engines are smoothand reliable. We haven’t had one incident withthe John Deere engine where it delayed us orcaused us to find an alternate barge.”Gellatly & Criscione continues to upgradeits fleet with double-hulled vessels with morecapacity and reliability. And Gellatly says healready knows what type of power will beaboard these new vessels: John Deere. “Theproof is in the pudding,” he says. “We lovethem.”Engines: John Deere PowerTech 6125H — a317-kW (425 hp), 6-cylinder, 12.5L, air-to-airaftercooled diesel engine. Dealer: KennedyEngine Co., Biloxi, Miss., (228) 392-2200.Distributor: Engines Inc., Weiner, Ark.,(870) 684-7361, www.enginesinc.comJohn Deere industrialengines receive EPAcertification for marineauxiliary commercialapplicationsJohn Deere engines are among thefirst choice for generator and pumpingrequirements in the commercial marineindustry. Several models of John Deereindustrial engines are now approved formarine auxiliary applications. Thesemodels include the 187-kW (250 hp)PowerTech 6068H, the 242-kW(325 hp) 6081H, the 317-kW (425 hp)6125H, and the 392-kW (525 hp)6125H. A marine auxiliary engine isdefined in 40 CFR Part 94 and clarifiedin EPA documents EPA420-R-05-008,“Test Procedures for Highway andNonroad Engines and Omnibus TechnicalAmendments, Technical SupportDocument and Summary and Analysisof Comments” and CSID-06-012“Portable Auxiliary Marine Engines –Interpretation of Installed”. In summary,an engine is considered a marine auxiliaryengine if (1) it is tied to the ship’sfuel, cooling, or exhaust systems, or (2)it is mounted on the vessel in such away that requires significant effort toremove it. For example, if a portableengine is designed with a quick-connectaccess to the onboard fuel supply orwith other hardware that allows theengine to tie into the vessel’s coolingor exhaust systems, EPA will considersuch engine installed. Even though it is“portable,” such an engine generallycannot operate without the fueling orother systems available on the vessel.In other words, it cannot be operatedonce it is removed from the vessel. If theinstallation meets the marine auxiliarycriteria, then the engine can be certifiedas a marine auxiliary engine.


RELIABILITYBoth the 6125H and the 6081Hare running non-stop insidetheir super-silent canopies.The 6081H works hard to keepeveryone cool.John Deere and New Way – awinning combination.One Cool LodgeWith daytime temperatures nearing45 C (113 F), the Singita Lebombo Lodgekeeps cool, thanks to John Deere generatorsA living memorial to President PaulKruger, the Kruger National Park (KNP)covers nearly 20,000 km 2 (5 millionacres). Providing much-needed sanctuaryfor South Africa’s exotic wildlife, itattracts almost one million visitors everyyear, financing its own future as itreminds guests of the need to protect theplanet’s most beautiful spots.The Lebombo Lodge is one of fourlodges run by Singita Private GameReserve. It was built in 2003 after SouthAfrica’s National Parks Board opened upa section of the KNP to private tender.“We were delighted to win the bid forthe finest concession site,” says JasonTrollip, general manager of SingitaLebombo. “We chose the 15,000-hectare(37,065 acre) N’wanetsi Concession,home to a huge range of flora and fauna,including the Big Five – lion, leopard,rhino, elephant and buffalo. For theactual Lodge, we developed theN’wanetsi Rangers Outpost, which hasstood at the confluence of the N’wanetsiand Sweni Rivers since the 1950s.”Minimal impact. The suites at SingitaLebombo are built on stilted decks on theedge of the cliffs, providing spectacularviews of untouched wilderness. “Rightfrom the start, our motto has been ‘touchthe ground lightly.’ So we’ve stuck tonatural building materials, and we’rekeeping a close eye on our operations sowe can minimize the impact we have onthe land – we’re the custodians of thisremarkable place, not its owners.”The Lebombo areaboasts the highestdensities of gamethat rangers haveever seen, includingthe Big Five.But although visitors enjoy the back-tonaturefeel of the lodge, they do expectcertain home comforts. “So far from thenational grid, our only option was generators,powerful enough to support boththe lodges and the staff villages. Ourmain requirements were 24/7 reliabilityand performance under harsh conditions.You can’t have an unreliable powersupply to the air conditioning or thefreezers when it’s nearly 45°C (113 F)!John Deere engines were the obviouschoice, as they’re known for good performanceunder the toughest conditions.”Minimal hassle. “I’ve beenimpressed,” continues Trollip. “We’verented three generators with a full maintenanceprogram that includes a monthlyservice. Two of the three run non-stop,and the oldest one has been going foralmost 32,000 hours. The two on theactual lodge site are inside super-silentcanopies, which keep the noise to anabsolute minimum. John Deere’sdistributor New Way sends an engineeronce a month, and that’s pretty much theonly maintenance they need. I must saythat New Way has been fantastic.They’re reliable and always on call! If weever need a fourth generator, naturallywe’ll go for another John Deere.”Engines: John Deere PowerTech6125H — a 310-kW (416 hp), 6-cylinder,12.5L, turbocharged diesel engine;John Deere PowerTech 6081H — a204-kW (274 hp), 6-cylinder, 8.1L,turbocharged diesel engine; John DeerePowerTech 6068T — a 85-kW (114 hp),6-cylinder, 6.8L, turbocharged dieselengine. Distributor: New Way Motor &Diesel Engineering Ltd., Johannesburg,South Africa, +27 11 680 5632, e-mail:newway@icon.co.zaPowerSource 11


RELIABILITYNo-sweat UpkeepServicing and maintaining John Deerepowertrain components is an easy way to makea living, according to this railroad mechanicThis Kershaw Model 46-6-2 ballast regulatorfeatures a John Deere powertrain comprised of aPowerTech 8.1L engine, coupled to a Funk pumpdrive and HMD Series 17000 transmission.The Mark III tamper raises, levels, and alignsrailroad track.This custom-built brusher cutter consists of aJohn Deere 120C excavator mounted, withoutits undercarriage and tracks, on a railroad car.One John Deere engines propels it along thetrack and operates the boom, while the otherpowers the cutter heads.Mike Delia says being responsible for keepingJohn Deere engines on the job makes him feel likethe bored home-appliance repairman featured in ahumorous series of TV commercials several yearsago. There just isn’t that much for him to do.Delia is the work equipment repair foreman forConsolidated Rail Corporation (Conrail). The terminaland switching freight railroad uses several dauntingpieces of equipment to maintain its 805-plus kilometers(500 mi.) of track and right-of-way. The majorityof that track is in New Jersey, but Conrail also operates lines in Philadelphiaand Detroit.Working under the supervision of equipment engineer Rick Maher, Deliaand Jeff Griffin are responsible for servicing and repairing the monstermachines Conrail uses to maintain track and right-of-ways in the SouthJersey and Philadelphia areas. Three of those machines are now powered byJohn Deere diesel engines. One is a Kershaw Model46-6-2 ballast regulator that also has a Funk HMDSeries 17000 transmission. It’s used to bevel andsmooth up the gravel ballast of the roadbeds thathold Conrail track in place.There’s also a Mark III tamper, built by Tamper (adivision of Harsco Track Technologies) then rebuilt byNorfolk Southern Railroad, one of Conrail’s parentcompanies. It features the PowerTech 6068H and aFunk HMD Series 33000 transmission. The tamperis used to raise, level and align track. Its clamp assembly latches onto the railsand moves the track as needed. Then, four work heads ram 16 vibratingtamping picks down below the ties to pack the ballast tightly so it holds thetrack in place.The third John Deere-powered machine was custom-built by RailConstruction Equipment Co. It’s a John Deere 120C excavator mounted,without its undercarriage and tracks, on a railroadcar. The boom can be outfitted with either of twohuge, interchangeable cutter heads. Its job is to chewup brush and trim or cut down trees that encroach onConrail tracks. The brush cutter actually has twoJohn Deere engines. One propels it along the trackand operates the boom; the other powers a hydraulicpump that drives the cutter heads.“These engines are terrific,” Delia says. “They runhard, at full rpm, eight hours a day and under punishingconditions. In cold, heat, you name it. They always fire right up andrun steadily ’til we shut ’em down.” He notes that he hasn’t had a singleengine problem with Conrail’s John Deere-powered maintenance equipment.“All we have to do is the routine service on them and they treat us real well,”he says.12 PowerSource


RELIABILITYThe tamper is powered by a PowerTech6068H fitted with a Funk pump drive andHMD Series 33000, four-speed transmission.Delia adds that John Deere engines are also the easiestto maintain of any he’s worked on during his 23 years asa mechanic. “The filters are all located in places thatmake them easier to swap out than on other equipmentwe maintain,” he says. “There are no panels to remove orthat sort of thing.”Delia also has high praise for the power John Deereengines deliver. “With the Brown Brontosaurus cutter headon it, we use the brush cutter to take down trees up to 10inches (25 cm.) in diameter,” he says. “You’ve got to havepower for that. And the tamper is a real beast. It actuallylifts up the whole railroad and moves it left or right, thenpacks the stone tightly under the ties. The whole time, theengine’s just screaming, but it never screams ‘Uncle.’”He says the John Deere engine and Funk transmission inthe ballast regulator make an ideal combination. “Havingplenty of horses and being able to shift on the fly are essentialwhen you’re pushing and dragging piles of stone, sometimesup to 100 yards (91 m),” he explains.“Reliability is also critical in our operations,” Delia adds.“We can’t have a machine break down on a main line, but wedon’t sweat that now. Since we got these John Deere engines,it’s been just great.”Engines: (ballast regulator) John Deere PowerTech 6081A— a 205-kW (275 hp), 6-cylinder, 8.1L, aftercooled dieselengine; (tamper) John Deere PowerTech 6068H — a 186-kW(250 hp), 6-cylinder, 6.8L, air-to-air aftercooled diesel engine;(brush cutter, travel and boom) John Deere PowerTech 4045D— a 60-kW (80 hp), 4-cylinder, 4.5L, naturally aspirateddiesel engine; (brush cutter, cutting heads) John DeerePowerTech 6068T — a 127-kW (170 hp), 6-cylinder, 6.8L,turbocharged diesel engine. Transmissions: (ballast regulator)Funk HMD Series 17000, two-speed transmission; (tamper)Funk HMD Series 33000, four-speed transmission. Pumpdrives: (ballast regulator) Funk Series 28000, clutch-driven,1:1 gear ratio, double-pad pump drive; (tamper) Funk Series59000, direct-drive, double-pad pump drive.A Perfect PatchPothole patching can be performedfast and efficiently by a single operatorthanks to the Magnum Spray InjectionPatcher built by Crafco Inc., of Chandler,Ariz.The Magnum patcher cleans the areato be repaired, applies tack coat, coatsthe aggregate with asphalt emulsion, andthen applies the mixture, all in one easycontinuous operation. “It’s the fastestway to lay a compressed patch withouthaving to pack it,” explains Hector Lara,Crafco engineer. “It’s probably twice asfast as conventional methods.”The power driving these functions isthe 60-kW (80 hp) John Deere PowerTech4045D engine, which performs three separatejobs. It powers the air compressorfor the emulsion, the lobe-type blowerthat moves the aggregate, and thehydraulics for auxiliary functions.“Dependability is important for thisapplication,” says Lara. “We have threefunctions coming off of the engine, andJohn Deere is such a stout product.”Government agencies continue to buya lion’s share of Magnum patchers.Municipalities and road departmentsin the states, as well as abroad, largelypurchase these trailer-mounted units.“John Deere engines are universallyaccepted because of the support that’savailable through the dealer network,”says Lara. “That’s why we pickedJohn Deere engines, and we hear nothingbut positive remarks from the field.”Engine: John Deere PowerTech4045D — a 60-kW (80 hp), 4-cylinder,4.5L, naturally aspirated diesel engine.Distributor: Western Power Products,Inc., Bakersfield, Calif., (661) 397-9155,www.westernpowerproducts.netOEM: Crafco, Inc., www.crafco.comCrafco combines speed and efficiency tocreate a top-notch pothole patching systemCrafco’s Magnum Spray Injection Patchercleans and then applies a mixture of aggregateand asphalt emulsion to a pothole. A singleJohn Deere 4045D powers the machine’s aircompressor, blower, and hydraulics.PowerSource 13


F ACTORY NEWSThe John Deere 6090H –Diesel of the Year 2006Naturally, when the John DeerePowerTech Plus 6090H was namedDIESEL magazine’s “Diesel of the Year2006” at the EIMA exhibition in Italy,we were proud. We’d produced aninnovative engine that meets thedemanding Tier 3/Stage III A emissionregulations and also delivers improvedperformance andfuel economy.Jacques Febvre,director of enginemarketing forEurope, Africa, theMiddle East andJacques Febvre Asia, explains.PowerSource: This award is for themost innovative engine. What drivesJohn Deere’s innovation?Jaques Febvre: Acommitment to offeringthe best value in all ourproducts – by listeningto customers’ requirementsand anticipatingwhat they’re going towant tomorrow.So when we starteddeveloping engines tomeet the new emissionrequirements, we knewcustomers wouldexpect more than justcompliance. We wereaiming to design arange of engines thatalso offers best-in-class performanceand fuel consumption. And that’sexactly what we achieved. In fact, the6090H’s efficiency saves operators upto a liter of fuel every hour! When you14 PowerSourceHigher efficiency and better performance as well aslower emissions – no wonder the John Deere 6090His DIESEL magazine’s “Diesel of the Year 2006”Star of the show – the 6090Hand it’s a well-deserved prize.look at trends in fuel prices today, youcan see why that’s so valuable – andwhat I mean when I say we anticipatetomorrow’s requirements.PowerSource: What’s so innovativeabout the technologies in the 6090H?How do they benefit operators?J. Febvre: Reducing NOx and particulatelevels is a compromise: reduce oneand you increase the other. And deterioratingthe air-fuel mix with exhaust gasrecirculation reduces power density andfuel efficiency. So we used EGR(External Gas Recirculation) toenhance engine efficiency, breathingand power density, while the VGT(Variable Geometry Turbocharger)increases engine response, with moreboost available on demand.And by using thelatest technologies, the6090H sets a startingpointfor compliancewith the Interim Tier4/Stage III B and FinalTier 4/Stage IV regulationsexpected between2008 and 2015.PowerSource: Whatapplications does the6090H target?J. Febvre:Applications whereoperating costs are key,in other words, wherepower density, performance andeconomy are as important as the initialinvestment. We began shipping theengines in June 2005, and we’veMr Romano Bellamico, general manager ofItalian distributor Rama Motori, receivesthe award on behalf of John Deere at EIMA(the main Agricultural and IndustrialExhibition for Italian and SouthernEuropean markets) on Nov. 12th, 2005.already had excellent feedback fromOEMs and from farmers who’vebought our new 8030 tractors,powered by the 6090H.PowerSource: A final word?J. Febvre: As a major supplier ofdiesel engines for off-road applications,we have a great track record for bothinnovation and environmentalresponsibility. Our first priority is ourcustomers, but we’re always pleasedto receive awards which recognizeour achievements.To win the award, the 6090H had toimpress DIESEL’s jury – industryexperts from 16 European countries.With a 20-year track record, the magazineis the reference for engines in theItalian agricultural and marine market,and its special feature on the 6090Hwill also raise the profile of our entirerange of PowerTech Plus engines (4.5L- 13.5L), which cater to a range ofapplications and budgets and offersimilar three-fold benefits.And this isn’t the only award the6090H has picked up – it also receiveda “Top 100 Product of the Year Award”from Construction Equipment. It’s thefifth time John Deere has receivedone of these awards, which highlightinnovative manufacturers who investin research & development, providingequipment users with greater productivity,efficiencies, and safety.Engine: John Deere PowerTech Plus6090H — from 168 kW (225 hp) to298 kW (400 hp), 6 cylinders, 9.0L,turbocharged diesel engines.


A Dual CelebrationJohn Deere Engine Works in Waterloo producesits one-millionth engine while celebrating30 years in the diesel engine businessJohn Deere Engine Works reached two notable milestonesin the engine business this spring. The Waterloo, Iowa, factorysimultaneously celebrated its 30th anniversary while it alsosurpassed production of its one-millionth engine.While this is a significantachievement for one enginefactory, this figure is just afraction of the overall totalproduction of John Deereengines worldwide, whichexceeds well over 5 million.This logo commemorates a newmilestone for John Deere EngineWorks in Waterloo, Iowa.To accommodate the risingglobal demand for theengines, John Deere nowmanufactures engines infive countries. In addition to the Waterloo, Iowa, factory,engines are also produced in Saran, France; Torreon,Mexico; Rosario, Argentina; and Pune, India.The one-millionth engine manufactured at Engine Works inWaterloo, Iowa, is a Tier 2/Stage II PowerTech 8.1L engine.It was installed in a John Deere 9996 cotton picker, a six-rowpicker that’s been dubbed by John Deere as the most powerful,most productive cotton picker the company has ever built. The261-kW (350 hp) air-to-air aftercooled engine that powersthis picker features an electronic governor that deliversconstant power, improved performance, and increasedproductivity when operating in wet or hilly field conditions.John Deere engines are the very heart of John Deerevehicles, and increasing numbers of other equipment manufacturersrecognize and appreciate their value, as well. In fact,John Deere engines also power many original equipmentmanufacturer (OEM) machines. That’s a huge increasefrom the few hundred engines sold to a handful of ag-relatedF ACTORY NEWSMaking a bit of history at John Deere Engine Works is this 261-kW(350 hp) PowerTech 6081H air-to-air aftercooled diesel engine.customers in the mid-1970s, when the company first beganmarketing engines to OEMs. Today, John Deere PowerSystems’ (JDPS’s) global customer base includes engines inthousands of applications.John Deere’s long-termcommitment of investmentsin factories andtechnology has madeJohn Deere a world leaderin off-highway dieselengine manufacturingand emissions technology.JDPS manufactures30-kW to 448-kW(40 hp to 600 hp) enginesfor use in a variety ofnon-road applications.The one-millionth engine wasinstalled into a John Deerebrandcotton picker, known asthe company’s most powerfuland productive.JDPS also manufactures and markets natural gas on-roadengines, marine engines, and drivetrain components.Sure, John Deere is proud of its milestones. But this isonly the beginning of the progress that this company willmake in the future in the development of the world’s mostpowerful, reliable, and fuel-efficient engines.CalendarLook for John Deere engines and drivetraincomponents at these upcomingtradeshows, conventions, and exhibits.AUGUST, 200629–31 Farm Progress, Amana, IA, U.S.A.SEPTEMBER, 200612–14 Husker Harvest, Grand Island, NE, U.S.A.OCTOBER, 20064-7 GeoFluid, Piacenza, ItalyNOVEMBER, 200628-30 PowerGen, Orlando, FL, U.S.A.DECEMBER, 200614-16 SAMATEC, Madrid, SpainJANUARY, 200724–25 World of Concrete, Las Vegas, NV, U.S.A.FEBRUARY, 200713–15 World Ag Expo, Tulare, CA, U.S.A.PowerSource 15


DKEDM226 Litho in U.S.A. (2006-07)

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