New drive – Curtain up for the technology of the future - DEUTZ Home

DEUTZLIVE
The magazine of DEUTZ AG Edition 1/2010
Technology
New names for new
technology
Expertise
How DEUTZ found a way
out of the crisis
New drive –
Curtain up for the
technology of the future
®

Photo: DEUTZ AG
Dr Helmut Leube
New drive
The 2009 financial year has been one of the
most difficult in DEUTZ AG‘s long history.
For the first six months of 2008, impressive
results were still being reported. Then two years
ago this summer an unforeseeable crisis began
to set in that went beyond the financial sector
and soon entered the real economy. For DEUTZ
this meant having to cope with severe setbacks.
What began as a consequence of poor speculation
by bankers, soon entered the real economies
of North America and Europe and resulted
in a dramatic drop in demand, primarily for mobile
machinery, our largest segment. Engine unit
sales more than halved going from 252,359 units
down to 117,961 units with the drop in revenue
being slightly less at 42.2 % and amounting to
g863.4 million. Operating profit before one-off
items crashed to g–46.3 million. But in this difficult
year we quickly took appropriate measures.
Since its start, the MOVE package of measures to
reduce costs and raise efficiency, has achieved
savings of around g136 million from material and
Editorial
overhead costs. However, personnel measures,
such as short-time working, temporary staff cutbacks,
early retirement and even enforced redundancies,
were still necessary to achieve long-term
reductions in fixed costs and to ensure our competitiveness.
In addition, over the past 12 months
we have sharply focussed on our working capital
and cash flow situations. Internal financing has
meant a positive operative cash flow situation despite
the severe collapse in sales. By the end of
2009, we had managed to survive the crisis practically
debt-free.
For the first time since the onset of the crisis, we
were able to report a clear rise in demand at the
year end. The fourth quarter confirmed the trend
with an approximate positive operating result.
DEUTZ has passed the low point of the crisis.
Looking to this year, we can affirm a clear continuation
of this positive development. Turnover
and sales for the first quarter of 2010 are above
expectations. A significantly improved order book
means we can expect 2010 to be much better
than 2009.
Find out on p.18 how DEUTZ set a new course
for the future while being in the midst of the biggest
crisis of current times. In spite of the severe
economic situation we kept looking ahead and
developed the two new TCD 2.9 L4 and TCD 3.6
L4 engines. They are also the central point of this
year‘s bauma stand (p.8). And it isn‘t just these
two that are new at DEUTZ. To highlight the technological
advance represented by the development
of our engines for Tier 4 interim emissions,
all DEUTZ engines from this emission stage will
receive new product designations. Find out on
p.10 how these will look.
Dear DEUTZ LIVE readers, we have shown that
even in times of crisis we do not lose sight of
what‘s important. Technological expertise and
the ability to demonstrate strength under extreme
conditions is what marks us out. Looking to the
future – that is DEUTZ. Let us look ahead together
and go into the future with new energy from our
new engines.
Yours,
Dr Helmut Leube
3

Contents
4 DEUTZLIVE 01/2010
Title photo
DEUTZ presents
the new 4-cylinder
TCD 2.9 L4 engine
10 With the introduction of
engines for the stricter EU
emissions stage IIIB/US EPA
Tier 4 interim, DEUTZ is
changing its range of model
designations
Title
8 New drive - Curtain up for the
technology of the future
In the midst of the crisis DEUTZ sets a future
course and develops two new engines

Photos: DEUTZ AG, Pixelio, Fotolia, Bomag, Flughafen Leipzig
Contents
10 New names for new technology
New product designations provide DEUTZ
customers with important product information
13 Top theme: Exhaust gas aftertreatment
DEUTZ symposium on exhaust gas aftertreatment
at bauma 2010
14 Restrained power
The power of a DEUTZ engine in the Bomag
“hybrid roller”
16 Super with DEUTZ
The new fl agship from Joseph Vögele AG:
The Super 3000-2 - powered by DEUTZ
18 How DEUTZ found a way out of the crisis
Following record results for 2007, the crisis then hit
DEUTZ. But the long-established company managed to
reverse the trend
20 Weightless with DEUTZ
DEUTZ provides transport at the
Leipzig/Halle Airport
22 DEUTZ at the top of world
In the world’s highest country DEUTZ
provides dependable energy supplies
Topics
3 Editorial
6 News
23 Press news
23 Reader activity
14 Powered by DEUTZ - the Bomag “hybrid roller”
20 Weightless with DEUTZ - DEUTZ in action at the
Leipzig/Halle Airport
22 Extreme conditions: Since 2009 DEUTZ has
had a presence in the Nepalese market
IMPRINT | DEUTZ LIVE Edition 1/2010 | PUBLISHED BY DEUTZ AG, Ottostraße 1, 51149 Köln (Porz-Eil) | RESPONSIBLE Janina Decker, Company Communication |
OBJECT MANAGEMENT Janina Decker, Phone: +49 (0)221 822 24 93, Fax: +49 (0)221 822 15 24 93, Email: decker.j@deutz.com | EDITORS Janina Decker | DESIGN department Agentur für
Kommunikation, Köln | CREATIVE DIRECTOR Yusuf Öztürk | LAYOUT Michael Göken, Nina Kanani | PHOTOS/ILLUSTRATIONS Janina Decker, DEUTZ AG, Shutterstock, Fotolia, Pixelio, Leipziger
Flughafen, Bomag, Vögele | PRINTED BY Druckpartner, Essen
5

News
Las Vegas
Strong showing
DEUTZ AG demonstrates forward-looking
at the World of Concrete in Las Vegas.
From 2 - 5 February 2010, DEUTZ was at
one of the USA’s most prestigious construction
trade fairs presenting its machinery
engines that meet the stricter US EPA
Tier 3/ Tier 4 interim emission standards.
A wide range of exhaust gas aftertreatment
components from the DVERT ® system also
awaited trade fair visitors. DEUTZ presented
DVERT ® components, filters and SCR
technology as display models as well as
exhibiting the TCD 2010, TCD 2011, TCD
2012 engine series. A special highlight
for visitors was a computer-aided simulation
of the brand new engine with the
preliminary project designation TCD 20XX.
Cologne
JIS centre opens
6 DEUTZLIVE 01/2010
DEUTZ at the WOC 2010
DEUTZ again demonstrates it is in the forefront of engine manufacture
optimisation by investing €2.5 million in a new just-in-sequence (JIS)
assembly centre at its Porz location in Cologne. Within a 12,000 m²
building, DEUTZ is optimising its assembly processes and material
management to deal with the increasing product diversity resulting
from new emissions legislation. The wide variety of individual components
are picked just-in-time in the required sequence. In many cases
they are then pre-assembled before being delivered to the assembly
lines. Suppliers send components to the JIS centre on just the day
required enabling a permanent reduction in on-site stock levels. To
manage the material, the components are made available in the form
of sequence boxes at more than 30 workstations.
The switch to delivery via the JIS centre already began in mid-2009.
Production management systems were switched to full sequencing
with different orders being lined up at assembly like a string of pearls.
With the required lead times, the JIS centre and suppliers can then
deliver just the right level of materials at just the right time. With the
implementation of JIT (Just in Time) / JIS (Just in Sequence) logistics,
DEUTZ is optimising its workflows within engine production. In future,
only those basic components used on all engine variants will be held
at the assembly line workstations with sequencing doing away with the
need for walkways.
Around 50 staff, who formerly worked within assembly, are to be employed
in the JIS centre on a two-shift basis. In their new roles they will
sequence supply up to 50 separate engine assembly workstations.
Ulm
500,000 DEUTZ engines from Ulm
A milestone has been reached at the DEUTZ plant in Ulm. At the turn of
the year, the 500,000st DEUTZ engine rolled off the production line at
the Ulm-Donautal site. The Ulm site went into production in 1967. The
team there is then able to draw on decades of experience in the design
and assembly of air-cooled and water-cooled engines. It all began with
production of the air-cooled FL312 V-engine, with the FL413 engine
series being added just one year later, a series that is still enjoying
success today as part of the product range.
In 1993 production commenced in Ulm of the 1015 water-cooled engine
series To date over 35,000 units of this engine type have left the
site in a multitude of variants. It became popular through its use in the
Dakar Rally, the world‘s toughest off-road motor race, with its proven
reliability and robustness helping many race teams to success. The Vengines
of the 413/513 and 1015/2015 production series deliver impressive
performance and efficiency whether on road in heavy goods
vehicles, on construction sites, in mines or on rails. They have made
Ulm the centre for air and water cooled engines with a displacement
over 8 litres. Ulm is also the centre for all DEUTZ‘s marine activity.
The relocation of production of the 912/913/914 air-cooled engine
series from Cologne to Ulm in late 2006/early 2007 marked the most
important turning point in the plant‘s recent history. The Ulm plant today
produces air-cooled and water-cooled engines with a power output
of up to 500kW for use in stationary equipment, construction equipment,
commercial vehicles and rail vehicles.
The 500,000st DEUTZ engine from Ulm

Photos: DEUTZ AG
Cologne
Volvo and DEUTZ sign new supply agreement
The Volvo Group has been working closely
for many years with the DEUTZ engine
manufacturer. In 1998 both companies
signed an agreement for the development
and supply of diesel engines with displacements
from 4-7 litres. The agreement was
made for a 15 year period and comes to
an end in 2013.
The new supply agreement will come into
effect from 1 January 2014. It covers the
further development of medium-sized
DEUTZ industrial engines for the European
COM IV and US Tier 4 final emission
standards. The agreement means DEUTZ
remains the sole supplier of 4-8 litre engines
for Volvo’s construction machinery.
Cologne
Friends Association established for DEUTZ AG
engine collection
In cooperation with the Cologne City
Museum, DEUTZ AG has established a
Friends Association for the preservation
and upkeep of its historical engine collection.
The aim of the „Friends of DEUTZ‘s
Engine Collection“ is to safeguard and
maintain DEUTZ‘s unique engine collection,
a collection that is also protected
through its registration as a German
national cultural asset. This unique and
historical collection goes back to the year
1875. Already in 1925, exhibits could
Cologne
Bosch, DEUTZ and Eberspächer set up joint
venture for diesel exhaust aftertreatment
On 9 December 2009, Robert Bosch
GmbH, DEUTZ AG and Eberspächer GmbH
& Co. KG signed an agreement to set up
a joint venture in diesel aftertreatment.
On 7 April 2010, the “Bosch Emission
Systems” joint venture was approved by
the EU Commission and may now begin
operations.
Bosch Emission Systems, based in Stuttgart,
is to utilize the core competencies
in exhaust gas aftertreatment from the
three participating companies, and to
offer complete modularised system solutions
for construction and agricultural
machinery as well as for commercial vehicles.
This includes electronic controlling
and, if required, burner technology
for the regeneration of diesel particulate
DEUTZ will also continue to supply engines
complying with the Euro 3, 4 and 5 emissions
standards for existing use in Volvo
commercial vehicles. “We pride ourselves
on the success of the collaboration and
look forward to it continuing over the long
term.” says Dr. Helmut Leube, CEO of
DEUTZ AG.
be viewed by the public in a company
museum. The association encourages
broad public access to the collection, e.g.
through visitor schemes as well as the
financing of new exhibits and restoration
projects.
Helmut Müller, who heads the history activities
for DEUTZ, holds the chairmanship
of the Friends Association. Its deputy is
Dr. Michael Euler-Schmidt, acting Director
of the Cologne City Museum.
filters. The products on offer are tailored
to mobile machinery such as excavators,
wheel loaders, tractors and combine harvesters,
as well as to stationary systems.
Other areas of usage are commercial vehicles
such as heavy goods vehicles and
buses.
The concept is based on a modularised
system. A large pool of standard components
enables custom-built exhaust gas
aftertreatment systems to be assembled
for any vehicle or any machine. “We have
made a name for ourselves as an engine
manufacturer who can provide individual
solutions for our customers. We are now
bringing this important know-how to the
joint venture and by doing so we are not
only investing in our own products, but
NOTICES | In brief
Management team
for DEUTZ Dalian now
complete
News
Since August 2007 DEUTZ AG and FAW Jiefang
Automotive Co. Ltd. (FAW), a wholly
owned subsidiary of China First Automobile
Works Group Corp. (FAW Group) in Dalian,
China, have been supporting the joint
venture DEUTZ (Dalian) Engine Co., Ltd.
(DDE). The Cologne engine manufacturer is
responsible for the joint venture’s industrial
management and last year introduced new
personnel to pivotal managerial positions in
order to hasten the young venture towards
profit-making.
The 41 year old Bernd Hoffmann has become
the Chinese company’s new CEO. The
mechanical engineer had previously spent
five years as head of the CLAAS Hungaria
Kft. in Hungary. He has also headed production
systems at CLAAS KGaA in Harsewinkel
in Germany.
With Stella Teng as the new CFO, the DEUTZ
Dalian Diesel Engine Ltd. management team
is now complete. The 53-year-old has worked
for, among others, the Pfizer company in
China. Teng, who has an MBA from the University
of Michigan, last held the CFO position
at DHL-Sinotrans in China.
With the joint venture located in the north
Chinese city of Dalian, DEUTZ is significantly
expanding its presence across the Chinese
market. DEUTZ Dalian manufactures and
sells diesel engines for commercial vehicle
as well as industrial applications. For the
2009 financial year, the joint venture manufactured
approximately 99,500 engines of
which around 6,700 were 4 to 8 litre engines
built on the basis of licensed DEUTZ technology.
also in the fast-growing market for exhaust gas aftertreatment
systems”, stated Gino Mario Biondi,
the Management Board Member for technology at
DEUTZ AG. By using practically only standardized
components means significant competitive advantages
in respect of cost, development time and validation
time. Modular systems also give flexibility.
Individually designed tubing solutions enable optimal
utilization of the restricted installation space
on mobile machinery.
Series production of the aftertreatment units for
diesel engines is planned to begin in the third quarter
of the current year. Around 100 staff from the
participating companies will be employed by Bosch
Emission Systems with 20 of these coming from
DEUTZ AG.
7

Title
New drive – Curtain up for the
technology of the future
DEUTZ demonstrates that it is forward-looking by
presenting at bauma 2010 two new engines,
the TCD 2.9 L4 and TCD 3.6 L4.
Their distinguishing features are a compact design, high performance
and proven reliability. The TCD 2.9 L4 is the new engine from DEUTZ.
DEUTZ is presenting the new engine for the fi rst time at bauma 2010.
It had been announced with the preliminary project designation
TCD 20XX.
Available in both naturally aspirated and turbocharged versions (with
or without a charge air intercooler) and equipped with cooled external
exhaust gas recirculation and 1,600 bar common rail high-pressure
8 DEUTZLIVE 01/2010
TCD 2.9 L4
injection, the ultracompact 4-cylinder 2.9 litre-series in-line engine
covers a performance range from 25 to 56 kW. The compact engine,
specially developed for extremely short and space-restricted installations,
offers high performance and torque with very smooth running.
The engine achieves a maximum 300 Nm of torque at 1,600 rpm.
A modular exhaust gas aftertreatment system has been designed to
meet the industrial machinery need for compactness and cost effi ciency.
A maintenance-free and cost-effective diesel oxidation catalytic
converter (DOC), along with a particle oxidation catalytic converter
(DOC + POC), can cater for most applications. A closed DPF option
(diesel particle fi lter) is also available.
For the TCD 2.9 L4 there is also a complete range of customer options
including effi cient lateral auxiliary drives and mass compensation
shafts. Oil change intervals at 500 h and a maintenance-free valve
train increase productivity and lower operating costs. Low noise levels

Photos: DEUTZ AG
give further cost savings by reducing insulation requirements.
The TCD 2.9 L4 gets its fi rst offi cial public showing at the DEUTZ AG
stand at bauma. The new engine had an initial showing at the Agritechnica
in Hanover in November 2009, albeit as a virtual presentation. A
computer assisted animation enabled trade fair visitors to get a preliminary
glimpse of the DEUTZ technology of tomorrow.
The TCD 2.9 L4 is however not the only new engine from DEUTZ. Whilst
in the middle of the most extreme economic situation of recent decades,
DEUTZ consciously invested in the future by developing the new
TCD 3.6 L4 engine.
The water cooled TCD 3.6 L4 has a power range of 50 to 85 kW and
achieves a maximum of 400 Nm of torque at 1,400 - 1,600 rpm. The
turbocharged 4-cylinder engine, available with or without a charge air
intercooler and cooled external exhaust gas recirculation, is equipped
TCD 3.6 L4
Title
with a 1,600 bar common rail system and impresses through its low
power to weight ratio and high power density. Long service intervals
also help to keep maintenance costs down. The TCD 3.6 L4, like all
DEUTZ engines, has extremely good cold-start properties and is therefore
suited for use in extreme climatic conditions. A particle oxidation
catalytic converter (DOC + POC) is available for exhaust gas after-treatment,
as well as having a DPF (diesel particle fi ltered) option.
With the introduction of new emission standards, the two newly developed
TCD 2.9 L4 and TCD 3.6 L4 engines tie in with the legendary
DEUTZ 2011-series, which remains in production for current emission
standards. “DEUTZ stands for innovations and best-in-class technology.
Our new engines combine maximum customer benefi t with
minimum operating costs. This will extend and further strengthen
our technological leadership,” emphasized Gino Mario Biondi, DEUTZ
Managing Director of Development and Production. $
9

Innovation
New names for
new technology
There are other signs of change at DEUTZ as well as the new TCD 2.9 L4 engine
being presented at bauma 2010.
Previous
engine designation
TCD 20XX L04
TCD 2010 L04
TCD 2012 L04
TCD 2012 L06
TCD 2013 L06
TCD 2015 V06
TCD 2015 V08
10 DEUTZLIVE 01/2010
New
engine designation
TCD 2.9 L4
TCD 3.6 L4
TCD 4.1 L4
TCD 6.1 L6
TCD 7.8 L6
TCD 12.0 V6
TCD 16.0 V8
Number of
cylinders
L: In-line engine
V: V-engine
Displacement in litres
(rounded)
Diesel engine
Intercooled
Turbocharged engine
DEUTZ is at the world’s largest
trade fair for construction and mining
machinery as a leading technological
provider of low-emission
diesel engines with a broad performance
range of 25-520 kW. With
the introduction of engines for the
stricter EU emissions stage IIIB/US
EPA Tier 4 interim, DEUTZ is altering
its entire range of model designations
to highlight this technological
advance.
Self-explanatory and succinct engine
designation codes will provide
customers with all the required
product information. The first three
letters give specifics such as turbocharger,
intercooling and fuel type.
This is followed by engine displacement
in litres as well as cylinder set
up and number. Engines still being
produced according to current and
earlier emissions standards are to
retain their existing designations.
At just a glance, the new designation
codes therefore provide a
unique aid to DEUTZ customers.
In the mid-range performance segment,
DEUTZ has extensively developed
its tried and tested 2012-series
in-line engines for the next
emissions stage. In the 70 to 115
kW performance range, DEUTZ can
offer customers the water-cooled
TCD 4.1 L4 engine, which delivers
a maximum torque of 610 Nm
at 1,400 to 1,600 rpm. The turbocharged,
intercooled 4-cylinder
in-line engine is equipped with a
1,600 bar DEUTZ common rail system
(DCR ® ) and cooled external ex-

Photos: DEUTZ AG
haust gas recirculation. The robust
engine design impresses through
its high power density, outstanding
reliability and long service intervals.
A range of customised options are
available for the 4-cylinder engines
including effi cient lateral auxiliary
drives and mass compensation
shafts. The modular exhaust gas
aftertreatment system provides a
closed diesel particle fi lter (DPF)
whose regeneration is aided by a
controlled aircore choke.
In the 120 to 180 kW performance
range, DEUTZ offers the watercooled
TCD 6.1 L6 with a maximum
torque of 1,000 Nm at 1,400 to
1,600 rpm. The robust 6-cylinder
in-line engine is equipped with a turbocharger
and intercooler, cooled
external exhaust gas recirculation
and an electronically controlled
DEUTZ 1,600 bar common rail
system (DCR ® ) with high-pressure
injection for power ranges up to
160 kW and 2,000 bar for top-ofthe-range
performance. The engine
impresses through its outstanding
cost effectiveness, long engine service
life and long service intervals.
A closed diesel particle fi lter (DPF)
with aircore choke regeneration for
INFO | Displacement
power ranges less than 130 kW,
and diesel burner regeneration for
power ranges greater than 130 kW,
enables the TCD 6.1 L6 to fulfi l the
requirements of the new emission
levels.
The water-cooled 6-cylinder TCD
7.8 L6 engine, with performance
ranges of 160 to 250 kW, is the
most powerful engine in the midrange
power class. It achieves a
maximum torque of 1,400 Nm at
1,400 to 1,600 rpm. The engine
has a turbocharger with a charge air
intercooler, cooled external exhaust
gas recirculation, wet cylinder liners
and a DEUTZ 2,000 bar common rail
(DCR ® ) high-pressure injection system,
and is designed for heavy-duty
operation. The high-performance
engine has excellent power density
and outstanding reliability with
long service intervals. The TCD 7.8
uses an exhaust gas aftertreatment
system to meet the heavy-duty requirements
of industrial machinery.
A closed diesel particle fi lter (DPF)
with active diesel burner regeneration
ensures maximum machine
availability under any conditions.
The TCD 12.0 V6 covers the 240 to
Displacement is one clear indicator of an engine’s classifi cation. It is
the sum of all the cylinders’ combustion chambers. For each cylinder,
the combustion chamber is calculated from the amount of travel available
to the piston (stroke) and the cylinder diameter (bore), using the
formula bore (cm 3 ) x stroke (cm).
Power = torque x rpm
Innovation
11

12 DEUTZLIVE 01/2010
390 kW performance range. The V-confi guration water-cooled
engine is turbocharged and intercooled, and is equipped with
wet cylinder liners and common rail high-pressure injection with
an injection pressure of 2,000 bar. The compact V-design enables
it to be used within extremely small installation dimensions.
Designed for heavy-duty use, the TCD 12.0 impresses
through its robustness and long maintenance intervals. With its
proven high-performance SCR technology, the TCD 12.0 is designed
for the needs of large, heavy-duty industrial machinery
for which fuel consumption is a major priority.
The high-end engine is the powerful TCD 16.0 V8. The watercooled
350 to 520 kW 8-cylinder engine rounds off the DEUTZ
range of products for the IIIB / Tier 4 interim emissions standards.
Equipped with a turbocharger, charge air intercooler and
wet cylinder liners, the TCD 16.0 generates a maximum torque
of 2,890 Nm at 1,400 rpm, and impresses through optimal performance
characteristics. A modern 2,000 bar electronic common
rail injection system combined with an SCR exhaust gas
after-treatment system achieves reductions in environmentally
harmful emissions. The compact V-engine design requires signifi
cantly less space and therefore reduces installation costs
for customers. $
TCD 2.9 L4 TCD 3.6 L4 TCD 4.1 L4 TCD 6.1 L6
TCD 7.8 L6
TCD 12.0 V6 TCD 16.0 V8

Photos: DEUTZ AG
Top theme:
Exhaust gas aftertreatment
DEUTZ symposium on exhaust gas aftertreatment
at bauma 2010
Because this year’s bauma focuses
on the range of applications
for construction machinery
and vehicles, then exhaust gas
aftertreatment will also take
on a central role. From January
2011 and commencing with performance
classes from 130kW
to under 560kW, diesel engines
for mobile machinery must comply
with EU exhaust gas stage
IIIB and US EPA Tier 4 interim.
These require a clear reduction
in particle and NOx emissions
For DEUTZ this means not only
complying with the differing
global emissions legislation but
also meeting customer requirements
as effectively and as economically
as possible as well as
providing them individually with
their power-drive needs. DEUTZ
is well prepared for emissions
reductions and demonstrates
its expertise again at this year’s
bauma. The challenges and innovative
technologies arising from
the new emissions legislation
are to be presented by DEUTZ on
21 April 2010 at a “DEUTZ modular
technologies for new emission
standards” symposium.
Numerous experts will be available
to answer questions on ex-
haust gas aftertreatment and to
provide information on the new
exhaust levels, the DVERT® system
(DEUTZ Variable Emission
Reductions Technology) as well
as the newly designed TCD 2.9
L4 engine. $
Technology
13

Expertise
Restrained
power
14 DEUTZLIVE 01/2010
The Bomag “hybrid roller”:
power from DEUTZ

Photos: Bomag
Customers from the construction machinery
branch require above all that the power units
of their equipment can cope with the highest
of demands and can demonstrate above average
capability and reliability. In addition, the
power units must be energy-efficient, low on
fuel consumption and environmentally friendly
by complying with the stricter emissions regulations.
Too much to ask? Not for DEUTZ. At
bauma 2010, Bomag presents a roller prototype
whose DEUTZ hybrid drive meets every
one of these requirements.
Global demands for CO 2 reductions
are leading to an increasingly
growing discussion on alternative
power drive designs.
Hybrids in the passenger vehicle
segment have been around for
years but remain the exception
for mobile machinery. Already
in 2007 DEUTZ was pioneering
the development of a hybrid
drive for a wheel loader for the
Atlas Weyhausen company. This
was a sensation for non-road
applications. The AR 60 wheel
loader has meanwhile found a
successor that is on the way to
being series-produced with the
DEUTZ hybrid drive (DEUTZ LIVE
reports).
The DEUTZ hybrid drive is also
highly suited to other construction
machinery. The compacting
of asphalt is ideal for utilizing
hybrid technology. Compacting
is characterised by a roller’s
nonstop reversing manoeuvres:
braking, direction change and
then a short burst of acceleration.
On top of this, the compacting
process requires an on
and off activation of a generator
system, which requires still more
power.
DEUTZ again takes a pioneering
role in collaboration with its partners.
At bauma 2010, Bomag,
the global leader in compacting
technology as well as a manufacturer
for earth, asphalt and
waste compacting equipment,
presents its original field tested
“hybrid roller” based on BW 174
AP AM, the most successful
Bomag roller with a market share
of more than 50 percent.
This “hybrid roller” uses a 47
kW TD2009 DEUTZ combustion
engine and a DEUTZ hybrid system
made up of an e-machine, a
high-performance battery, along
with powerful electronics and a
maximum usable 22kW of electric
power. The hybrid system’s
e-machine is integrated into the
combustion engine’s flywheel
housing thereby saving space.
Expertise
The electronics and battery are
easily accessible by being located
in the roller’s door.
The operating principles of the
DEUTZ hybrid system are both
simple and efficient. The electric
motor takes energy from the
battery and assists the main
power unit as required, e.g.
when switching to vibration or
during acceleration. This then
covers the peaks of when performance
is needed. The concept
enables a significantly reduced
nominal performance level from
the diesel engine, i.e. downsizing,
meaning no need for complex
exhaust gas aftertreatment
systems. During low engine-load
phases, e.g. during braking or
vibration system deactivation,
the e-machine functions as a
generator and recharges the battery.
Mechanical kinetic energy
can then be recuperated. During
optimal work phases the diesel
engine always operates at its
most efficient. A further feature
of the system is its automatic
start/stop function. When running
idle, and when consumers
are shut down, the diesel engine
automatically switches off.
Movement of the drive lever, or
the activation of a consumer,
switches on the diesel engine
via the e-machine. This takes
place without any delay so that
the operator can begin work immediately.
This significantly reduces overall
fuel consumption and the associated
emissions of CO2. Initial
tests have been very promising
with diesel savings of up to thirty
percent.
The tested prototype can be
seen at bauma 2010. Advanced
compacting engineering coupled
with frontline engine technology -
making the BW174 AP hybrid into
a 21st century roller. $
15

Expertise
16 DEUTZLIVE 01/2010
The new construction or resurfacing of motorways,
major or minor roads and airports cannot happen
without pavers.
Vögele offers crawler equipped road-pavers in
power classes for any use. What they all have in
common is economy combined with reliability. The
newly developed SUPER 3000-2 is the new leader
in large pavers in performance capacity, technological
leadership and ergonomic comfort. With a
lay down rate of up to 1,600 t/h and a pave width
of up to 16 m, the paver can quickly lay down seamless
and very wide asphalt surfaces as well as
completing major construction projects. The main
requirements from a paver are reliability and the

Photo: Vögele
Super with DEUTZ
ability to cope with heavy-duty stresses. Vögele
therefore relies on the powerful drive technology
from DEUTZ. The paver is equipped with the
highly modern DEUTZ 6-cylinder TCD 2015 V06 4V
diesel engine. This compact and powerful engine
achieves a maximum power of 300 kW at 1,800
rpm. The TCD 2015 is equipped with an electronic,
magnetic valve injection system that provides low
fuel consumption and high economy. Compared to
other large pavers of this class, consumption is
low at around 217 g/kWh. The 6-cylinder engine
naturally complies with the current EU-COM 3a and
US EPA Tier 3 emission regulations.
Expertise
bauma is the trade fair for new products and innovations for the construction
machinery sector. It then goes without saying that the DEUTZ name is constantly
referred to there. Just in time for bauma 2010, Joseph Vögele AG presents its
new flagship, the Super 3000-2 road-paver that leads the world’s largest paver
fleet. And what drives it? DEUTZ, of course.
The SUPER 3000-2 can also be operated in an
“ECO-Mode” of 292 kW at 1,500 rpm thereby
further reducing the paver’s already low fuel consumption
and noise levels.
The 2015 engine’s compact dimensions reduce the
amount of installation space required and therefore
also installation costs. $
17

Expertise
How DEUTZ found
a way out of the crisis
Just short of 286,000 engine sales was the record result for DEUTZ in the 2007 fi nancial year. The forecast
for 2008 was promising – engine sales were to reach the 300,000 level. Metaphorically speaking, the engines
were revving at levels never experienced before. The DEUTZ Board of Management and staff looked promisingly
to 2008 and expected another successful year.
The fi rst six months of 2008 seemed to fulfi l all expectations for
DEUTZ, and the previous year’s success look as if it was to continue.
But then in September 2008, a report from the USA hit the
headlines: the US Investment Bank Lehman Brothers appeared to be
bankrupt. The reason was the bursting of a property bubble. Since
the end of the 1990s, increasing numbers of Americans had got
into debt in order to fulfi l their dreams of house ownership. The US
property market boomed and houses purchased on credit continually
rose in price enabling lending banks to give out even more credit.
To fi nance the increasing levels of credit, banks began to trade the
outstanding loans and offered them to the stock markets as securities
with guarantees of high returns. The US economy began to falter,
the Federal Reserve Bank raised base rates and this led to lending
banks then raising their interest rates on loans. This had the consequence
of many house owners being unable to repay loans and then
losing their homes.
The securities, which were based on the property bubble, dramatically
lost value with many banks having to resort to fi nancing the
18 DEUTZLIVE 01/2010
losses through short-term and low interest loans to other banks.
An increasing lack of confi dence then led to banks refusing to give
each other credit. On 15 September, stock markets around the world
collapsed with the German share index dropping to its lowest level
since October 2006.
The crisis then extended beyond the fi nancial sector to the real
economy with a force that nobody had predicted. What began as a
property crisis then slowly hit DEUTZ. For the third quarter of 2008,
DEUTZ reported a weakening in levels of incoming orders and sales,
particularly for engines of less than four litres. It was soon clear that
this was not a short term fi nancial crisis but a fundamental and long
term shift in the global economy. The outlook for 2008 had to be
adjusted to the new economic situation and the fi rst measures had
to be implemented.
DEUTZ took a decision in October 2008 to commence the “MOVE”
package of measures. The package contained short term measures

Photos: DEUTZ AG, Shutterstock, Fotolia
intended to secure short term
earnings as well as structural
measures for long term improvements
in performance. The package’s
cornerstones included a
new pricing policy, increased
productivity and efficiency targets
for manufacturing, R&D and
quality control as well as a lowering
of material and overhead
costs.
Staff levels also required adjusting
to the drop in demand. In
the second half of 2008, DEUTZ
was compelled to implement an
initial course of staff restructuring
that continued into 2009 and
eventually led to a reduction of
more than 700 personnel. The
Board of Management and employee
representative boards
also agreed on short time working,
first for production and then
for all company departments
excluding R&D. These measures
were also to continue through to
the spring of 2010.
For the first half of 2009, DEUTZ
had to report drastic downturns
on incoming orders, sales and
turnover. With the background
of an ongoing global recession,
overall sales and turnover had
halved compared to 2008. The
collapse of sales in the US
meant up to 60 % losses in the
under 4 litre engine segment.
These heavy downturns pushed
DEUTZ ever deeper into a trough
whose way out was unknown.
Despite all the uncertainties in
making any prognoses, DEUTZ
focused on maintaining and expanding
its technological lead
and continued to heavily invest
in research and development in
order to create a solid basis for
future growth.
Staying power and
technological expertise
While more than 85 % of staff in
Germany went on to short-time
working, in the development
departments work continued at
full speed on the new emission
standards EU Stage IIIB/ US
EPA Tier 4 interim and EU Stage
IV /US EPA Tier 4, which are to
come into force from 2011 to
2015 in western Europe and
North America. At the Paris In-
termat trade fair in the spring
of 2009, DEUTZ was able to
present at one of the world’s
most prestigious construction
machinery trade fairs, its entire
range of four litre products
that comply with the new emission
standards. The engines
received an excellent response
and acceptance from the DEUTZ
customers.
A further step included organisational
restructuring of
the company. After the Board
of Management was reduced
from four to three members in
March 2009, there was then a
significant slimming down by 35
percent of staff below management
board level. Operational
functions at the Cologne and
Ulm locations were amalgamated
to achieve greater structural
efficiency with faster decisionmaking
procedures and a flatter
hierarchy.
In the midst of the crisis DEUTZ
then took another step towards
the future. Together with Robert
Bosch GmbH and J. Eberspächer
GmbH & Co. KG, DEUTZ signed
a “Memorandum of Understanding”
on collaborating on the
development, manufacture and
marketing of diesel exhaust gas
aftertreatment systems for the
non-road sector.
At the time of signing in the autumn
of 2009, there appeared
to be a slight stabilisation taking
place for the first time for
over a year. Although this stabilisation
was still at a low level,
the trend, having already been
evident in the second quarter,
was confirmed by there being
demand for DEUTZ engines and
services in the third quarter of
2009 despite the ongoing difficult
economic situation. In
September 2009, DEUTZ was
able to achieve a satisfactory
DEUTZ at the Intermat 2009 - sets future course during the crisis
performance for the first time
in months, mainly through
the progress made from the
“MOVE” package of measures.
DEUTZ reaches a trend
reversal
Despite all its cost-saving measures,
DEUTZ kept investing
heavily in research and development.
This enabled the new TCD
2.9 L4 and TCD 3.6 L4 engines
to be virtually presented to the
public at the Agritechnica 2009.
They are examples of DEUTZ’s
technological lead that it wants
to expand on into the future.
The future began in the spring
of 2010. In March of this year
Expertise
DEUTZ could report that it had
survived the crisis practically
debt-free. This was made possible
not only from the €136m
savings from “MOVE” but also
a systematic management of
working capital. The financial
crisis has still hit DEUTZ hard.
Turnover dropped by more than
42 % to around €863m and engine
unit sales of 118,000 were
not even half the level of the previous
year. But the worst seems
to be over. The hard hit engine
segment for construction machinery
has clearly recovered
with orders currently exceeding
expectations. Short-time working
could also be lifted across
the entire company. The outlook
for 2010 is for a significant rise
in sales and turnover.
In hindsight all these factors
make one thing clear: A crisis is
always a challenge. It demands
being able to think differently,
to be resilient and to know your
strengths. Above all to be active
and not reactive. Over the past
year DEUTZ did not just react
but acted by investing in future
technology despite being in the
midst of a recession. During the
crisis, DEUTZ set a course for
profitable growth and now goes
strongly into the future reenergized
by its new engines. $
19

Technology
Weightless
with DEUTZ
The Leipzig/Halle Airport is, at
eighty years of operation, not
only one of Germany’s most
established airports but since
1990 has gradually expanded
to become one of Europe’s most
modern. It has a well-functioning
and modern infrastructure and is
an ideal travel hub, being located
in the centre of Europe. Passenger
aircraft are dispatched
on the two 3,600 m runways and
air freight comes and goes on a
24-hour basis. What appears to
be practically weightless generally
isn’t, with the devil being in
the detail.
At a height of tens of thousands
of metres, aircraft seem to move
effortlessly through the clouds.
But on the ground they need
the sturdy help of aircraft tugs
to move safely between take-off
and park positions. The Goldhofer
AST 2R 210 is one such
aircraft tug. Five of this type are
being used at the Leipzig/Halle
Airport, and there are a total of
nine from Goldhofer that use
DEUTZ engines. The AST 2R210
20 DEUTZLIVE 01/2010
is multi-talented among towbarless
aircraft tugs. For the fast,
reliable and safe ground transport
of 100-300 ton aircraft,
these tugs set real benchmarks
thanks to their powerful engines.
They enable Airbuses and Jumbo
Jets to be effortlessly coordinated
between park, take-off and
landing positions. The powerful
and compact tug’s gripper arm
attaches to the aircraft’s nose
wheel, a hydraulic platform lifts
it, and the tug tows the aircraft
to the required position.
A tug with a powerful
diesel heart
A piggy-back weighing tons, the
aircraft trailing way behind the
tug with only a “Follow Me” vehicle
to show the way – this requires
a powerful engine! With
the DEUTZ TCD 2012 L06, the
tugs are equipped with a powerful
diesel heart. Available in
robust 4 and 6 in-line cylinder
versions, the water-cooled 2012
engine is characterized by a high
power density of 67 – 155 kW
at 2,400 rpm and complies with
emission standards for mobile
machinery according to EU-Nonroad
2004/26/EU Stage IIIA and
US EPA Tier 3. The slender engine
design also provides maximum
flexibility. The TCD 2012
is also economic through the
DEUTZ high pressure injection
common rail system (DCR®).
Pushback vehicles with DEUTZ
TCD 2012 engines
The so-called pushbacks can
also be performed by aircraft
tugs. A pushback manoeuvre is

Photos: Flughafen Leipzig/Halle
Technology
For most people airport atmospheres trigger feelings of wonderment. Within the large halls and long walkways
you soon get that familiar holiday feeling, and a glance towards the planes landing and departing makes you long
to get away. But for arrivals and departures to function smoothly, a lot of behind the scenes support is required.
DEUTZ LIVE took a look at the Leipzig/Halle Airport and discovered that this airport also relies on tried and
tested DEUTZ expertise.
required for aircraft which are
nosed at the boarding gates.
The majority of jet aircraft are
unable, or are not permitted, to
reverse under their own power.
Aircraft are also often positioned
where they are unable to
turn by themselves, especially
at major airports. JBT-Aerotech
also use the DEUTZ TCD 2012
to power the two pushback vehicles
in service at the Leipzig/
Halle Airport. There are two
pushback methods. Either a
push bar, similar to a tow bar, is
used or a nose tug is employed
which, similar to a normal tug,
attaches to the nose wheel. This
enables much faster moving of
the aircraft. The aircraft is then
pushed onto a taxiway where it
can then proceed to take-off under
its own power. This is a demanding
task for the tug engines
because the aircraft’s turbines
start-up during pushback and
as soon as there is enough distance
from the departure building.
This is necessary so that
the aircraft can then quickly exit
the taxiway.
Leipzig/Halle Airport
as a European hub for DHL
The Leipzig/Halle Airport is not
just important for passenger
aircraft. In 2008 the Deutsche
Post World Net, decided to use
Leipzig/Halle as their European
DHL hub. The central German
airport then became one of the
most important freight hubs in
Europe. Around 50 DHL cargo
aircraft use the Leipzig/Halle Airport
daily, and nothing functions
without DEUTZ. DHL recently ordered
a further 98 Mulag tugs
to add to the existing fleet of
150. These aircraft tugs, which
ensure the forwarding of several
hundreds of postal containers
every day, are also equipped
with the DEUTZ TCD 2012. $
21

Rubrik Life
DEUTZ at the top of world
Between the world’s most highly populated states, the autonomous region of Tibet’s People’s Republic of China
in the north, and India in the south, west and east, is the state of Nepal, on average the world’s highest
country. To the north and east lie a major section of the Himalaya range including Mount Everest, whose summit
at 8,848 m above sea level is the highest point on earth, as well as seven other of the world’s highest peaks. In
this country, whose climate poses many challenges, DEUTZ has a presence with its air-cooled engines
that provide reliable local energy supplies as diesel gensets..
For the inland state of nearly 30
million inhabitants, with many
living in the Himalayan region,
each day poses fresh challen-
ges. There are more than 16
hours of power cuts daily, and
this in a country where more
than forty percent live above
22 DEUTZLIVE 01/2010
3,000m. The majority of Nepalese,
around 85%, live on the
land with 15% being urban dwellers.
The most populated centre
remains the Kathmandu valley,
where nothing functions without
energy supplies. It is not
just the banks and offices that
require a guaranteed supply of
energy, but also the hotel sector
- Nepal is a magnet for tourists.
Around 300,000 people travel
to Nepal each year with tourism
bringing in €50m, around 30%
of total income. Temperature
and air pressure represent daily
challenges to humans and machines
alike in a country where
some regions even today remain
undeveloped. The air cooled
DEUTZ 914 series engines are
the insider tip for this mountai-
nous region. They are easy to
use and extremely economical.
Furthermore, the robust DEUTZ
engines can always be depen-
ded on irrespective of the monsoon
climate temperatures ranging
between -20°C to +32°C.
The engines are equipped with
an extra kit that is adapted to
the region in which they are to
be used. There are specific kits
for desert applications, for use
in artic conditions or for tropical
heat and humidity conditions.
The air cooled DEUTZ engines
in the gensets are available in
performance classes from 29 to
152 kVA. Gensets with DEUTZ
engines are a real alternative in
the Nepalese market because
demand for energy there is continuously
growing. A supply grid
caters for the major centres
where energy is required, and
hydroelectric plants feed an
additional 550 megawatts into

Photos: Andreas Blakkolb Fotolia, cedric BASSET Fotolia, Timo Fotolia, DEUTZ AG, Pixelio
the network But this still does
not guarantee an uninterrupted
energy supply. Rohini Tapaliya,
president of the German-Nepalese
board of trade, introduced
the air cooled engines exclusively
into the local market with
a genset launch in November
2009. $
Press news
December 2009 – April 2010
READER ACTIVITY | Prize game
What is shown in this close-up photograph?
A) TCD 3.6 L4 B) Roller
C) Tug D) Burner
Send your answers via e-mail to
decker.j@deutz.com or by fax to
+49 (0)221 822 15 24 93.
Closing date is 15 June 2010.
From the correct entries we will draw
winners for an A5 leather writing case.
Winners of the prize draw from
edition 2/2009: AdBlue-Tank
Winner: Roland Goller,
Kurt-Schumacherstr. 11,
95326 Kulmbach, Germany
Take part and win:
This time an A5
leather writing case
with an exclusive
DEUTZ logo
beckons the
winner.
Service
23