INSIDE 14

MOTOREX laboratories State-of-the-art infra-structure at your service.

INDUSTRY 18

Medical engineeringInnovative production for precision forceps.

TOPIC 8

LowSAPS technologyFOCUS QTM for clean snowcats.

NO. 91/42 I DECEMBER 2010 I www.motorex.com

REPORT 10

Swiss high-tech automotive engineeringPacked full of high-end hybrid technology, the SWISSAUTO POLO REX is headed straight for the international automotive market. Fredy Barth drove it for us.

WITH 2010

RACING RESULTS

2

IN MOTOR SPORT, YOU CAN’T AFFORD TO MAKE COMPROMISES, HE SAYS. UNLESS YOU DON’T WANT TO WIN.

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 how our oils are helping companies from a wide range of industries to reap success: www.motorex.com

WHY DO YOU THINK HE SWEARS BY US?

Winfried Kerschhaggl, Motor Sport Director KTM / WP

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CONTENTS EDITORIAL

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

NEWS

4 MOTOREX in the news

TOPIC6 LowSAPS motor oil for snowcats

HYDRAULIC OIL8 Winter sport regions turn to OEKOSYNT HEES

REPORT

10 Swiss high tech on the international

automotive market

INSIDE14 The latest from the MOTOREX lab

EXPORT16 Storm Motor storms Finland

INDUSTRY18 Innovative production processes for

precision forceps

PRACTICE20 For heavyweights: GREASE 219

BOX

22 Cool ideas/Did you know…/Comic

MOTOREX creates value

Dear customers, partners, readers,

dear colleagues,

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

44

RACING PRO 4T NOW AVAILABLE IN SAE 5W/30

OVER 25,000 DIESEL ENGINES EVERY DAY

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 collabora-

tion with KTM. RACING PRO 4T SAE

5W/30’s special formula and addi-

tives 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 four-

stroke engines. The

result is maximum

racing performance

combined with opti-

mum clutch action.

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 en-

gines built here.

Countless machining centers grind,

mill, turn and bore the various alu-

minum and cast iron engine compo-

nents in three shifts. MOTOREX

COOL-X spindle coolant is used in

the spindles with great success:

there have been no spindle down-

times due to cooling problems since

the switch to COOL-X. And COOL-X

can stay in the system for two full

years. When the time comes, a

trained maintenance team (photo)

changes the fluids during the sum-

mer break.

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.

BIOGARD CHAIN OILS REFORMULATED

UTTO POWER PACKAGE FOR CONSTRUCTION EQUIPMENTThe new MOTOREX UTTO CF (Univer-

sal Tractor Transmission Oil) in SAE

10W/30 viscosity is specially de-

signed for use in heavy-duty construc-

tion 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.

MOTOREX IN THE

NEWS

55MOTOREX MAGAZINE I DECEMBER 2010

“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 suspen-

sion 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

CLEAN WINDSHIELD WITHOUT VOCS

KTM 350 SX-F WITH A

MOTOREX EXTRA

Available immediately, MOTOREX

offers a VOC-free all-year windshield

wiper fluid concentrate and a VOC-

free 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 wind-

shields 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).

This modern LowSAPS motor oil

meets the stringent requirements for

the latest generation of trucks (Euro

4 and 5) with de-NOx catalytic con-

verters, 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’ strin-

gent requirements with regard to

extended oil change intervals, wear

protection, engine cleanliness, etc.

Always observe manufacturers’

recommendations. Contact your

MOTOREX partner for more

information.

FOCUS FE SAE 5W/30 COMBINES FUEL ECONOMY AND LOW SAPS

A world first from MOTOREX has

met with great interest in the press

and among many leading metal

processing companies. SWISSCOOL

TRESOR coolant-lubricant concen-

trate now uses new technology

which protects the emulsion effec-

tively 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, ami-

nes, etc. SWISSCOOL TRESOR also

guarantees top cutting perfor-

mance and the highest human and

environmental safety characteri-

stics. Together these properties

SUCCESS FOR SWISSCOOL TRESOR provide unparalleled cost-effec-

tiveness. The powerful advantages

of the new MOTOREX technology

and the strong positive response in

the press have persuaded many

renowned companies to progressi-

vely switch to SWISSCOOL TRESOR

in their machining centers.

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TOPIC

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 innova-

tive exhaust gas treatment systems running economi-

cally 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

FOR LOWER EMISSIONSTHE RIGHT MOTOR OIL

Snowcats with diesel particulate filters need a modern LowSAPS motor oil to run at their best.

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7MOTOREX MAGAZINE I DECEMBER 2010

combustion, formation of sulfate ash in the exhaust

gases is also affected by contamination from ash-contai-

ning 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 inte-

grated low-SAPS technology. The combination of an inno-

vative 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 parti-

culate 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 practi-

cal 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

• 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.•

The latest diesel engines wouldn’t run without electronic

assistants. Future engine management systems will use

even more electronics.

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.

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

8

HYDRAULIC OIL

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.

MOTOREX magazine: “Your region uses only rapidly

bio degradable hydraulic oils. Why is that?”

Willi Tremp: “As a region that depends on tourism, un-

spoiled nature is our most important asset. That’s why,

in keeping with our corporate vision, we use environ-

mentally 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’ re-

commendations. 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.”

WHITE SKI TRAILS

Perfectly conditioned ski trails de-

pend 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.

GREEN ON

“Extended change intervals and

high environmental compatibility

are important factors for us”

9

Photo: Sauer-Danfoss

MOTOREX MAGAZINE I DECEMBER 2010

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 factory-

filled 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 absolu-

tely 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 snow-

cats? Just contact your MOTOREX partner for tech-

nical advice. •

Willi Tremp regularly takes hydraulic

fluid samples and sends them to

MOTOREX for analysis.

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 compo-

nent 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.

High-performance hydraulic pump on test equipment at Sauer-Danfoss.

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REPORT

Over 300 companies in Switzerland, mostly small and

medium-sized enterprises (SMEs), are involved in pro-

duction for the international automotive industry. They

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.

The SWISSAUTO POLO REX engine compartment with electric motor, power electronics and range extender –

this Swiss technology is drawing lively interest from auto manufacturers.

Switzerland, land of mountains, watches, chocolates… and cars! Auto-mobiles 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.

the automotive worldSWISS HIGH TECH FOR

of tomorrow

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 manu-

facturers offer outstanding quality at competitive prices.

Total production volume in 2010 is again expected to

reach some 70 million vehicles.

“New technologies in the automotive industry”

11MOTOREX MAGAZINE I DECEMBER 2010

KNOWLEDGE CHANGES HANDS

Research and development continue to play a very special

role in auto manufacturing. Without the requisite tech-

nologies, 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

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.

In the SWISSAUTO POLO REX (REX = range extender), the

team from Burgdorf has gathered a number of inno-

vations into one winning technology package. This

“electrified” vehicle based on a VW Polo is equipped

with a Brusa hybrid synchronous electric motor deli v-

ering 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 de-

veloped by SWISSAUTO, along with energy recovered

from the braking system, charges the lithium ion poly-

mer battery (14 kWh).

Successful research and development depends not only on brilliant ideas,

but also on quality resources and specialized staff.

The battery pack is installed space-efficiently beneath

the trunk cover. No trunk room is sacrificed.

“The team has gathered a number of innovations

into one winning technology package!”

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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 capa-

ble 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 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 achieve-

ment 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

about 800 km and the car can accelerate its 1,245 kilo-

grams 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 astonish-

ingly high for a gasoline engine. Its specific consumption

values are comparable to those of a modern direct-injec-

tion 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

CO2-neutral basis.

The REX always runs on electric power; the range ex-

tender’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 combus-

tion engine’s catalytic converter is also pre-heated after

the electric motor starts. Once the converter has reached

operating temperature, combustion can start and con-

tinue 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 conven-

tional 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

The one-cylinder, 0.3-liter internal

combustion engine supplies 26kW

of power and is directly connected to

the 30-kW Brusa generator.

The crankshaft (left) and camshafts

of the 300-cc range extender

engine are equipped with low-

friction roller bearings.

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.

“The SWISSAUTO team worked closely with the

specialists at MOTOREX to minimize engine friction”

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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 50 kW 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!”

Fredy Barth took the SWISSAUTO POLO REX for a test run for MOTOREX

magazine and clearly enjoyed himself.

dependability. Examples include components for high-

pressure 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 in-

terior linings and corrosion-resistant chassis.

A COMPACT BUNDLE OF INNOVATION

The SWISSAUTO POLO REX combines a number of futur-

istic 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 lithi-

um 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. •

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SA

AG

BRUSA Elektronik AG supplied the high-efficiency

performance electronics for the POLO REX; testing

on the electric motor test bed.

14

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.

AUTONOMOUS AND FORWARD-LOOKING

MOTOREX is currently capable of conducting over 95%

of analysis and development processes in its own labo-

ratory. This is especially important for technologies that

have not yet been patented. Tribology experts are con-

stantly inventing new analytical methods and inge-

nious 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

FOR OUR CUSTOMERS

The Atom Emissions Spectrometer (AES) rapidly and precisely identifies trace elements such as wear components

(metals) and additives.

RESEARCH, DEVELOPMENT AND ANALYSIS

“New analytical methods”

INSIDE

15MOTOREX MAGAZINE I DECEMBER 2010

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 condi-

tion 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 represen-

tative 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 calculat-

ed from these figures: This is where test values are com-

pared with specification tolerances. This phase provides

information on shear stability, lubricity, etc.

3. Infrared readings: By comparing with reference sam-

ples, 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 opera-

tion – 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 ad-

ditives 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 parti-

cularly 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 com-

pelling products and well-received services from

MOTOREX. •

Rapid, precise analysis of incoming raw materials and production batches saves

time and enhances productivity.

Every day the MOTOREX lab receives a large number of customer samples

for quick, high-precision analysis.

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.

16

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 equip-

ment ranging from top brands to affordable alterna-

tives. 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

MOTOREX IN FINLANDSTORM MOTOR OY:

For its 40th anniversary in 2008, Storm Motor Oy moved to a new headquarter with central warehouse and an

impressive retail shop.

EXPORT

17MOTOREX MAGAZINE I DECEMBER 2010

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-busi-

ness 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 – in-

cluding 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 satis-

faction. Storm markets and advertises extensively and

is one of the leading advertisers in Finnish motorcy-

cling 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, creat-

ing 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 manag-

ers 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 improv-

ing 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

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.

A strong team (l. to r.): Sirkka Storm (Vice President) and Jyrki Storm

(founder and CEO) in front of their “favorite products” from Switzerland.

18

INDUSTRY

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.

PRECISION FORCEPS FOR ENDOSCOPIC SURGERY

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 per-

formed 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

Alligator and biopsy forceps are available in diameters from 1 to 5mm and in flexible or rigid versions in lengths up to 200cm.

19MOTOREX MAGAZINE I DECEMBER 2010

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 pres-

sure stability. SWISSCUT ORTHO NF-X meets all these

requirements with aplomb. Through ongoing develop-

ment 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 gener-

ation of ORTHO products is also risk-free for human

health and the environment and thus helps create better

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.

The forceps jaws are connected by joints with a pull mech-

anism. Here, a wire is laser-welded to the mechanism

under optical magnification.

As important as a high-performance machining center: the choice of machining

fluid has a significant impact on the production process and 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

• 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

working conditions. This not only has a positive effect on

the atmosphere in the workplace, but also helps reduce

maintenance and disposal costs.•

Mate Bekavac

20

PRACTICE

The capabilities of the ever-more powerful construction equipment used in earth-moving work are astonishing. And the loads on grease-lubricated 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 equip-

ment operates every day knows all about constant

heavy loads. Wheel loaders, excavators, cranes, convey-

or 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 heavy-

duty grease to protect all lubrication points reliably.

HANDY SOLID LUBRICANTS

The new heavy-duty GREASE 219 is a semi-synthetic lithi-

um 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

KEEPS CONSTRUCTION EQUIPMENT FIT

To keep equipment operating with low wear, automatic lubrication systems have to be refilled regularly with the right grease.

TECHNICAL GREASE 219

21MOTOREX MAGAZINE I DECEMBER 2010

Regular application of lubricant to lubrication points that

are not connected to an automatic lubrication system

prevents unpleasant surprises.

GREASE 219 is available in 400g cartridges and 17kg contain-

ers and can be easily loaded into mobile greasing systems.

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 with-

stand 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

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 specifica-

tions under DIN 51502.

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 identi-

cal 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 heavy-

duty option to the company’s range of technical greases. •

The four-ball apparatus is used to test the lubricant’s

pressure resistance up to the point at which the balls

weld together.

“This grease can withstand almost

any climatic challenge”

22

OTTOREX

BOX

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 coolant-

lubricant from MOTOREX. Turning and milling opera-

tions with this efficient and highly economical coolant-

lubricant 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

DID YOU KNOW THAT KWC FAUCETS ARE PRODUCED WITH MOTOREX?

Since 2007, a team of specialists from Gasser Felstech-

nik AG has been regularly traveling to Maarmorilik in

Greenland, where the northernmost passenger cable-

way 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.

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 pre-

pared 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. •

COOL IDEAS

COMPRESSOR OIL TESTED

ABOVE POLAR CIRCLE

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

Ph

oto

: K

WC

AG

23MOTOREX MAGAZINE I DECEMBER 2010

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, tooth-

pick, tweezers.

Article No: 450630

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 strip-

per, reamer and punch, ring, stainless steel toothpick, tweezers.

Article No: 450338

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.

A CUT ABOVE THE REST!

Peter Julen, Technical Director Zermatt Bergbahnen

THERE ARE THOSE WHO MAKE COMPROMISES, AND THERE ARE THE OTHERS. HE’S ONE OF THE OTHERS.

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 year, a challenge that allows no compromise. Setting radically new quality standards, never settling for the fi rst solution that comes along, but always insisting on the best: that’s something MOTOREX also stands for. And why we are precisely the right partner for Zermatt Bergbahnen. Find out more about how our oils are helping companies from a wide range of industries meet their ambitious targets: www.motorex.com

WHY DO YOU THINK HE SWEARS BY US?

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