Engine

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Engine Equipment Development Lead Time
Requirements are Significant Due to

• The Non-Integrated Nature of the Industry
• Number of Applications
• Proposed Technologies are Not Add On
• Technology solutions need to be developed

2
Market Specification Development Criteria
Parasitic Starting Loads, Inertia Requirements
Marketability, Aesthetics
Durability Requirements
Cycle Time of Operation, Charging Systems
Cost, Size, Weight Constraints
15 Standard Engine Development Criteria
Required Horsepower, Torque, PTO Loads
Operating Environment
Engine Controls, Governoring, Speed
Cooling Management
Fuel Systems and Carburetion
Vibration Systems
Exhaust Systems
Maintenance Related Accessories
Engine Configuration, Space Limitations
Safety of Operation
3
Requirements from Proposed Emission Controls

• Addition of Catalysts
• Will require new muffler guards or relocation of
  muffler.
• May require redesign of plastic guards, plenums
  and hoods.
• Addition of Evaporative Controls
• Will require new fuel tank design
• Will require addition of carbon canister and
  mounting hardware

4
Typical Product Development Cycle

• Develop hardware
• Engine manufacturer tests hardware
• Engine manufacturer works with OEM to apply
  hardware to application
• Engine manufacturer revised hardware to meet OEM
  specifications/application
• Engine manufacturer provides test samples to OEM
• OEM does development testing on sample hardware
• OEM and retailers develop distribution plans to
  segregate California products
• Upon approval of OEM, engine manufacturer
  provides production modified engine
• Engine manufacturer certifies product for sale in
  California
• OEM tests and approves production engine
• Engine manufacturer start to ship engines

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The engineering review for one engine model would
be required on over 100 pieces of equipment. One
of our large customers has 65 models of which
20-30 would require testing.
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Metal Versus Plastic Tanks

• Square or Rectangular tanks common in horizontal
  engine applications can be closely approximated
  in metal with a heavy cost penalty -- 6
  increase.

metal
plastic
4 quart tanks
8
Application Constraints on Walk Mower Fuel Tank
Design

• The integrated nature of walk mower fuel tanks
  prevents metal tanks from being duplicated.
• Limitations on walk mowers
• Loss of Geometry Definition/Detail
• Fuel Volume/Run time
• Increased package size
• Reduce number of engines in pallet
• Increased cost
• Additional mounting hardware required
• Changes required to major components
• Replacement of all fuel tank and shroud molds

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Walk Mower Tank Geometry
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Investment -- One Example

• Gas Tanks for Intek Engines
• Three different fuel tank configurations to
  accommodate OEMs/applications
• 10 molds
• Millions of dollars of tooling
• Shrouds
• 4 Shroud/Styling Packages for one engine
• 4 Tools _at_ 110,000 per Tool
• Fuel caps
• Five Different Fuel Caps Used in Production for
  one engine
• Total of 32 Cavities