1 APRA Global Connecon January 2015 take engines, components such as drivetrains, fuel pumps, as well as starter motors and fully remanu- facture them, strip them down, clean them, take the broken parts that are not workable anymore, have them re-smelted and replaced with new or remanu- factured parts.” They can sell these reman parts and engines as genuine Renault remanufactured products with a warranty that is equivalent to that of a new part, and are able to sell these products at a substantial reduction in price to the customer. Fur- thermore, “they are able to make a significant profit margin on what it would have cost to buy a new part. The reason being is that, by remanufacturing, they are able to retain around 80% of the original materials, which helps buffer them from raw mate- rial price increases and volatility.” At the same time they are able to maintain the embedded energy, water and carbon those parts contain. The Foundation have helped Renault to think about the role of reman in the context of their broader business, within the circular economy and “the ways that the process can be enhanced by linking the reman plant and the design department that conceives engines and other component parts, so at the end of their reuse period they can be remanufac- tured more effectively.” The Foundation also works with Philips which remanufactures medical devices such as Ultrasound Automove Parts Remanufacturers Associaon 4460 Brookfield Corporate Dr., Ste. H, Chanlly, VA 20151-1671 CHANGE SERVICE REQUESTED PRSRT STD U.S. POSTAGE PAID Permit #6194 Springfield, VA GLOBAL CONNECTION GLOBAL 25th Year | No. 1 | January 2015 Official Publicaon of the Automove Parts Remanufacturers Associaon Inside This Issue Andrew Morlet Interview ........................ 1 Industry Calendar .............................. 1 Kripli’s Corner .................................. 2 Duxes Internaonal Forum 2014 .................. 3 Classified Ad ................................... 3 New Members ................................. 3 Auto Electric Corner ............................ 4 Automechanika Shanghai 2014 ................... 6 Webinar on Market Potenal ..................... 7 New Product Announcements ................... 10 HDRG Nominaon ............................. 12 Magnetos .................................... 14 List of Adversers ............................. 15 Remanufacturing Fundamental to a Circular Economy Worth in Excess of USD 1 trillion per annum Reman Industry Focus (RIF) spoke to Andrew Morlet, CEO of the Ellen MacArthur Foundaon, about their work and the importance of remanufacturing as the world transions towards a circular economy By John Daly / [email protected]Isle of Wight, U.K. / Tue Nov 18, 2014 Dame Ellen MacArthur made yachting history when she broke the world record for the fastest solo circumnavigation of the globe in 2005. After retiring from professional sailing she directed her energy towards accelerating the transition to a circular economy. The Ellen MacArthur Foundation, setup in 2010, works with global business and education to implement an economic framework which is, in essence, regenerative or restorative by design. I spoke to Ellen MacArthur Foundation CEO, Andrew Morlet, about the potential of the circular economy and the integral part remanufacturing plays in its future. The Foundation has numerous Circular Economy 100 members including global corporations, emerg- ing innovators, regions and governments work- ing to implement circularity, alongside several key Global Partners. Three of these main partners including Renault, Cisco and Philips all undertake remanufacturing activities. Andrew explained that the Foundation works with remanufacturing companies by helping them “develop programs that support their mission within the sphere of the circular economy.” The Foundation helps these companies identify potential for collaboration initia- tives and possible opportunities for “improving the market conditions for the recapture of materials, bottlenecking or unlocking aspects of the supply and value chain.” Their role is to understand the issues their members, which span the entire spec- trum of the circular economy, must contend with. Remanufacturing in particular is “one area signifi- cantly underutilized internationally and we are very keen to promote remanufacturing, refurbishment, product service systems and business models that allow companies to get their products back at the end of use.” One partner that remanufactures, Renault, was the first corporate backer of the Foundation. They have a long history of remanufacturing, which began with the acquisition of the Choisy Le-Roi automo- bile plant, near Paris in 1949. At the plant “they — continued on page 12 Industry Calendar 2015 Heavy Duty Remanufacturing Group Summit January 26 Las Vegas, NV Heavy Duty Aſtermarket Week January 26–29 Las Vegas, NV Auto Tech Expo March 12–14 Jacksonville, FL ERA Trade Show March 13–14 Davenport, IA APRA Europe Technical Workshop April 23-24 Paris (France) Automechanika Chicago April 24–26 Chicago, IL APRA Electrical Clinic May 1–2 Chicago, IL ReMaTec 2015 June 14–16 Amsterdam, Netherlands PAACE July 14-16, 2015 Mexico City Visit APRA ONLINE: www.apra.org
Transcript
1APRA Global Connection January 2015
take engines, components such as drivetrains, fuel pumps, as well as starter motors and fully remanu-facture them, strip them down, clean them, take the broken parts that are not workable anymore, have them re-smelted and replaced with new or remanu-factured parts.” They can sell these reman parts and engines as genuine Renault remanufactured products with a warranty that is equivalent to that of a new part, and are able to sell these products at a substantial reduction in price to the customer. Fur-thermore, “they are able to make a significant profit margin on what it would have cost to buy a new part. The reason being is that, by remanufacturing, they are able to retain around 80% of the original materials, which helps buffer them from raw mate-rial price increases and volatility.” At the same time they are able to maintain the embedded energy, water and carbon those parts contain.
The Foundation have helped Renault to think about the role of reman in the context of their broader business, within the circular economy and “the ways that the process can be enhanced by linking the reman plant and the design department that conceives engines and other component parts, so at the end of their reuse period they can be remanufac-tured more effectively.”
The Foundation also works with Philips which remanufactures medical devices such as Ultrasound
Automotive Parts Remanufacturers Association
4460 Brookfield Corporate Dr., Ste. H,Chantilly, VA 20151-1671
CHANGE SERVICE REQUESTED
PRSRT STD U.S. POSTAGE PAID Permit #6194
Springfield, VA
GLOBALCONNECTION
GLOBAL25th Year | No. 1 | January 2015
Official Publication of the Automotive Parts Remanufacturers Association
Remanufacturing Fundamental to a Circular Economy Worth in Excess of USD 1 trillion per annumReman Industry Focus (RIF) spoke to Andrew Morlet, CEO of the Ellen MacArthur Foundation, about their work and the importance of remanufacturing as the world transitions towards a circular economy
Dame Ellen MacArthur made yachting history when she broke the world record for the fastest solo circumnavigation of the globe in 2005. After retiring from professional sailing she directed her energy towards accelerating the transition to a circular economy. The Ellen MacArthur Foundation, setup in 2010, works with global business and education to implement an economic framework which is, in essence, regenerative or restorative by design. I spoke to Ellen MacArthur Foundation CEO, Andrew Morlet, about the potential of the circular economy and the integral part remanufacturing plays in its future.
The Foundation has numerous Circular Economy 100 members including global corporations, emerg-ing innovators, regions and governments work-ing to implement circularity, alongside several key Global Partners. Three of these main partners including Renault, Cisco and Philips all undertake remanufacturing activities. Andrew explained that the Foundation works with remanufacturing companies by helping them “develop programs that support their mission within the sphere of the circular economy.” The Foundation helps these companies identify potential for collaboration initia-tives and possible opportunities for “improving the market conditions for the recapture of materials, bottlenecking or unlocking aspects of the supply and value chain.” Their role is to understand the issues their members, which span the entire spec-trum of the circular economy, must contend with. Remanufacturing in particular is “one area signifi-cantly underutilized internationally and we are very keen to promote remanufacturing, refurbishment, product service systems and business models that allow companies to get their products back at the end of use.”
One partner that remanufactures, Renault, was the first corporate backer of the Foundation. They have a long history of remanufacturing, which began with the acquisition of the Choisy Le-Roi automo-bile plant, near Paris in 1949. At the plant “they
— continued on page 12
Industry Calendar 2015Heavy Duty Remanufacturing Group SummitJanuary 26Las Vegas, NV
Heavy Duty Aftermarket WeekJanuary 26–29Las Vegas, NV
Auto Tech ExpoMarch 12–14Jacksonville, FL
ERA Trade ShowMarch 13–14Davenport, IA
APRA Europe Technical Workshop April 23-24 Paris (France)
Automechanika ChicagoApril 24–26Chicago, IL
APRA Electrical ClinicMay 1–2Chicago, IL
ReMaTec 2015June 14–16Amsterdam, Netherlands
PAACE July 14-16, 2015 Mexico City
Visit APRA ONLINE: www.apra.org
2 January 2015 APRA Global Connection
Dr. Salvador Munoz Zarate Product Line Leader WABCO REMAN Solutions Hannover, Germany
November 26, 2014
Dear Dr. Zarate,
Thank you for your leadership in working with the Remanufacturing Industries Council (RIC), the Motor & Equipment Remanufacturers Association (MERA), and the Automotive Parts Remanufacturers Association (APRA, including the APRA North America, APRA Europe and APRA Asia Pacific Divisions) to develop consen-sus definitions related to the industrial practice of remanufacturing for submission to the International Resource Panel (IRP) of the United Nations Environment Programme.
Our members are committed to working together to improve the worldwide appreciation of remanufacturing, and the important benefits it brings to the global community, in terms of environmental benefits, resource conservation, and economic growth. We believe that international movement of materials and components is essential for the successful growth and sustainability of remanufacturing, without which these benefits cannot be realized fully.
In order to further the understanding and appreciation of remanufacturing, the member organizations of RIC, MERA and APRA support the definitions of “Remanufacturing” and “Core” listed below, in the context of the Basel Convention.
REMANUFACTURING: After the remanufacturing process, the equipment or part fulfils a function which is at least equivalent compared to the original equipment or part. The remanufacturing process restores existing cores, using standardized industrial processes in line with specific technical specifications.
CORE: A core is a used equipment or part, intended to become a remanufactured equipment or part. During reverse logistics, it is properly protected, handled and identified for remanufacturing to avoid damage and to preserve its value. A core is not waste or scrap and will not be reused before remanufacturing.
We urge the IRP to recognize the intrinsic value of remanufactured products and how remanufacturing supports economic growth while reducing its environmental impact. A clear distinction between “hazardous waste”, as defined by the Basel Convention, and materials being responsibly shipped for remanufacturing will be essential for the sustainable growth of this important industry.
Sincerely,
Derek Guest, PhD Executive Director, Remanufacturing Industries Council
John Chalifoux President and COO, Motor & Equipment Remanufacturers Association
Joseph W. Kripli President, Automotive Parts Remanufacturers Association
Kripli’s CornerHappy New Year:
Well, it’s a new year and the APRA is off and running, address-ing issues for its members and planning seminars and sympo-siums. First up is the HDRG (Heavy Duty Reman Group) on the Monday, January 26, before HDAW starts
up and being held at the Mirage. We have some great speakers from Westport talking about CNG engines. If you are in the Heavy Duty or Com-mercial Vehicle side of the business, then this is the show for you.
I would like to bring to everyone’s attention the efforts being made by a number of associa-
tions to address the Basel Convention and their description of “waste product” and how not to confuse “waste” with “cores”. Here is the letter that APRA, MERA, and RIC has sent to the Basel Convention:
I am always questioned about what is APRA doing for me, the member, well, we are battling different political organizations constantly for the benefit of Remanufacturers around the world. This is how your dues are used to keep your rights as Remanufacturers and to protect you from over zealous organizations who are trying to do the right thing, but don’t understand the con-sequences when you label everything as “waste”.
I always welcome response or rebuttle to my com-ments at [email protected]
Special Projects Director Kathy Olson [email protected] / Ph: 703-968-2772, ext. 117
European Office: Gregor Schlingschroeder [email protected] / Ph: 011 49 2541 80068-18 Fax: 011 49 2541 80068-21
APRA European Office Neustrasse 8 48653 Coesfeld GERMANY
Send All News & Articles To: APRA, Attn: George Davis 4460 Brookfield Corporate Drive, Suite H Chantilly, VA 20151-1671 [email protected]
COPYRIGHT, 2015 / AUTOMOTIVE PARTS REMANUFACTURERS ASSOCIATION Printed by: Gannett Offset, 6883 Commercial Dr., Springfield, VA 22159
The APRA Global Connection newspaper is published as a membership service by the APRA. The opinions expressed in the articles in this news-paper are those of the author of the articles and not the publisher. While every reasonable attempt has been made to assure that the information in this newspaper is accurate, the publisher assumes no responsibility for any omissions or errors, nor for the application of any advice or sug-gestions in any particular situation. Due to space limitations, all items published are subject to abridgement. Unsolicited items will not be returned. The APRA Global Connection newspaper subscription rates are $15 for one year, or $25 for two years.
APRA EXECUTIVE COMMITTEE Chairman: Joe Kripli • First Vice Chairman: Tim Roth • Treasurer: Omar Cueto • Secretary: Jay Robie • Immediate Past Chairman: Nick Staub • Past Chairmen: Dennis Jacinto, Gary Phillips
The APRA Global ConnectionTechnical, Management and Association News from the Automotive Parts Remanufacturers Association
DRIVESHAFT FABRICATION MACHINERY
WESTPORT MACHINE WORKS, INC.700 Houston St., West Sacramento, CA 95691
Duxes International Remanufacturing Forum 2014 and Remanufacturing International Exhibition 2014
I attended the Duxes International Remanufacturing Forum 2014 and Remanufacturing International Exhibition 2014 in Shanghai December 3rd through the 5th 2014. The Expo consisted of a trade show, where APRA had a booth. Overall there were probably 25 booths. In China, remanufacturing is a grow-ing industry. The focus is on developing programs to allow remanufacturing to take hold in the Chinese economy the way it has taken hold in the United States. Admittedly it's difficult to believe but the focus really is on the Chinese market. The Chinese remanufacturing market is expected to reach 800,000 engine units and a combined 8 million starter, alternator, and transmission units per year. China has begun 42 pilot remanufacturing programs. They will not produce any further pilot programs for remanufacturing. There are some restrictions only parts within the scope may be remanufactured. A defined testing proto-col is required. An independent production line from new parts is not required but it is recommended. Authorization to remanufacture is required from the OE. Although this seems flexible because two reman-ufacturing companies, who happened to be APRA Members, are part of the pilot. Neither of these compa-nies has a strong affiliation with an OEM.
The government's focus is to welcome and encourage foreign remanufacturing investors. The govern-ment is working towards changing the laws to be more favorable for remanufacturing.
Among the speakers, was Zhu Sheng from National Key Laboratory for Remanufacturing. He stated that remanufacturing provides a tremendous opportunity for waste reduction and energy use reduc-tion. Further, that remanufacturing can extend the life of equipment. During the remanufacturing process, upgrades are made to equipment that increase its efficiency and modernize it. Additionally, the cost of remanufactured part is approximately 70% of a new part. Their technical focus is presently on the restoration of metal surfaces. This includes engine blocks, pivot points in construction equip-ment, and other things.
China believes that there is a technical gap between China and the West at the present time. They hope that the focus of government, engineering, and people can propel the sustainability that remanufacturing offers.
George DavisAPRA Technical Director.
Dr. Rolph Steinhilper, University of Bayreuth.
Opening CeremonyGeorge Davis delivering the Keynote Address
VIP Panel
For SaleBusiness in Toronto, Ontario, CanadaFil-More has been providing premium remanufactured and new clutch assemblies for automotive, light and heavy-duty vehicles since 1980. We operate out of our own building located in Toronto. Our dedicated and knowl-edgeable employees have a combined experi-ence of over 100 years in the clutch business.
We are selling the business as we would like to retire.
field current on the ground side, that is to say it is an “A-circuit” regulator.
The alternator, regardless of its higher then normal turn-on speed, has a very efficient power curve and can produce its maximum 70-amp ratings at about 3000 RPM. There are not many cores available for building a stock, but rebuilding this alternator is a straight forward operation with no surprises.
Generator to Alternator Conversion
Replacing the generators with alternator in some older applications, especially the ones that the aes-thetics is not of concern but the results matter, like an old working tractor—is something that is often done by many rebuilders. And when the installation and wiring is done in-house and done properly, the results could be very impressive and satisfying.
A farmer cus-tomer of ours just needed such modifica-tion because of many flood lights they had added to their 1964 IHC model 806D tractor, obviously for
chores they do year around and even at night. They were close enough that actually drove the tractor in!
The original 35-amp generator may have sufficed for charging the battery and lighting up a headlight or two, but certainly fell short handling a bank of additional flood light that were installed in this machine. (Figure-4)
After investigating the application catalogs and inspecting the tractor, we learned the later models
bulb will fix it, a sluggish power window that the customer thinks a little lubrication will free it up, and burned out connectors to the blower motor resistors and circuits that the customer expects to be fixed with just a new fuse, are all common scenarios that proper inspection and diagnostic work needs to be done by qualified technician to determine the culprit. This doe not necessarily works to the customer expectation every time.
Delco 7-SI Alternators
This family of alternators that has gained a lot of popularity in marines and industrial application (mostly forklifts) are showing up more for rebuild-ing. Due to lack availability of major components like rotor, stator, SRE or DE housings, they are mostly replaced with the new ones or aftermarket version of the originals. But some service parts like rectifier, regulator and brush holders are now available, and it does not take much to successfully rebuild them if major components are not needed.
An interesting factor is the price of the replacement units. Where there are some that are reasonably priced, but a nearly identical one with just one or two digits off may cost 2 or even 3 times as much. I can-not see much difference in them that commands such a wide range in price difference, but obviously the industry suppliers have their own reason.
A recent one we had for rebuilding had a 19020609 part number (Lester 8460), where the OE tag also identified it as a suitable marine alternator with SAE J1171 qualifi-cation, but it actu-ally was used on a forklift. (Figure-2)
Further investiga-tion showed that the rectifier had avalanche diodes with a 26V avalanche voltage range and it also included a diode trio built into the rectifier. The rotor’s slip-ring is the same as the one used on CS-130D alternator rotor and can be installed and will work fine in this alternator if needed.
The voltage regulator is also a little different as the 2 terminals on them are marked “S” and “I”, rather than the common S and L. I am not sure if the letter “I” is for “Ignition” or “Indicator” but is not used for bench testing the regulator according to available literature from WAI.
A brief hook-up diagram of the regulator can be seen in Figure-3, showing the terminal identification for testing. Since the alternator has a diode-trio, then this regulator is obviously designed to control the
Auto Electric CornerMohammad Samii
Going only by customer’s words regarding the prob-lem they may have with their vehicle can turn into unexpected surprises. At times the problem turns out to be quite different than what they had thought.
We had this 2002 Ford Windstar van that was towed in and dropped out in our parking during the weekend. The owner dropped off the key on next working day, mentioning as he was driving down the highway, he heard a loud noise and then stopped. He made a quick inspection himself and found out that the starter has fallen off the motor! And wanted us to look into it, repair or replace the starter and have it mounted securely. The problem seemed a little odd the way he explained it because it is rare for a work-ing starter to just fall off the engine.
The van was pulled in, and when hoisted and inspected, it was revealed to fix it, it may need a starter but what it needed foremost was an engine and a transmission!
Obviously a connecting rod had came off of a piston, swung around and went through the oil pan, and had hit he starter so hard that busted it off of its mount, breaking it away with a piece of transmission housing still attached to its mounting bolts...! (Figure-1)
The customer was invited to come over to see it him-self, as explaining the problem over the phone may be construed as unbelievable. He showed up, and was shown the extent of the damage, and of course it was decided that the repair was not feasible and the van needed to be put to rest.
There are many cases that the customer’s expectation and fixing the problem is quite different than what is actually needed. Inoperative headlights where the connectors are melted which the customer thinks a — continued on page 5
Figure-1 Damaged Engine and Broken Off Starter of WindstarFigure-3 7-SI Regulator Pin Identification
Figure-4 806D Tractor’s Original Generator
Figure-2 7-SI’s Forklift Alternator with Marine SAE Tag
5APRA Global Connection January 2015
the same process as Honda alternators with “C” terminals. Mitsubishi used this system on Gallant and Eclipse, but later on it proliferated to more models like Mirage, Lancer and Outlander, using alternators such a 13878 and 11377 which all have a 4-pin regula-tor with the “G” terminal. (Figure-7)
The “G” terminal which is also called Generator Gain Control by Mitsubishi performs no function except when it is pulled down (grounded) by PCM, the charging system voltage drops and alternator basi-cally shuts down. This feature can be easily tested by available test leads such as Jimco’s TB-75, where grounding the white test-lead’s wire will stop the alternator from charging.
The problems that we see and are prevalent in the field are the complaint about the lack of charging on newly installed alternator, where a detailed diag-nostic shows the G-pin is pulled low. This could be because of a wiring issue such as being inadver-tently grounded by a body shop or the installer of the add-on units, or a defect by PCM that keeps this wire grounded. At any case, as long as this wire is pulled low (to ground), the alternator would not function, regardless of multiple replacement.
Well, that’s all for this issue, until I see you again...keep up the good work.
Mohammad Samii can be reached via email to [email protected], or his website at www.sammysautoelectric.com
of this tractor were equipped with a 10-DN alterna-tor. Since we wanted a better option, we decided on a 7154 10-SI alternator with swing-type brush and a 72-amp stator. Once the alternator was built, we mea-sure a healthy 80-amp output from the unit.
The large diameter generator pulley was also replaced with a smaller diameter one, still accom-modating the ½ wide belts used on the tractor, with some minor changes in the upper bracket.
I decided to use the original wiring to the generator for the alternator, thus we needed to find the regula-tor to access its terminals. For those familiar with this tractor know that the regulator is installed on a panel underneath the steering wheel pedestal. But access to it requires removal of a few cover panels surround-ing the wheel and various shift levers; all in a very tight cab enclosure.
Nevertheless, the regulator was found, the “GEN” wire was attached to “BAT” wire so the other end of it was hot and now on the alternator output, and the warning light wire was also located and was con-nected to the “FLD” wire of the generator which we used for the alternator’s warning light. This all meant by using the existing wires, we did not have to run a new wiring loom under the tight engine cover. A loop was also made to provide the “Sense” wire to terminal “2” of the alternator, and this completed our wiring. While there, we also fixed the warning lights for the charging system and oil pressure.
The results were quite impressive for both; we and the customer. They could turn all the lights and the alternator was handling the load with ease. This was certainly a job that perhaps our farmer customer could not have done as well as we did, no matter how much instruction we could have provided him. After seeing the work and the complexity, they also agreed with my assessment and were very happy with the results. (Figure-5)
A brief “C” & “G” Terminal Review
Going by a couple of recent calls regarding a Mitsubishi alternator’s “G” terminal and an Acura’s “C” terminals, it appears there are still some confu-sion regarding the function and operation of these pins, and thus a little review and discussing the sys-tem on such alternators may be necessary...again!
We know a “C” terminal exist in certain Hondas, Acura and other such vehicles’ alternator that PCM by pulling it down—meaning grounding it or bring-ing it to near ground—can virtually stop the charging system, alas bring the system voltage down to 12.6
Volts. This feature is normally used for many reasons such as, fuel economy, soft start delay, or WOT (wide open throttle) applications where PCM lowers the alternator load when senses a fully charged battery
and low load, or when a sudden drastic demand for engine power is called for. During this period, however the alternator is not charging or is charging very little, there will be no alternator warning light illumination at all.
Different systems oper-ate this feature differently. For instance, in modern Honda/Acura’s, PCM mon-itors the Electronic Load Detector signal to see what are the demands, and if the
demand are low enough and some other criteria are met, then the “C” terminal is pulled low, which is to say it turn the alternator into a trickle charger for the battery, keeping the set voltage not at 14 but about 12.6V, or slightly higher.
On some Isuzu vehicles (using 13745 alternator) which have this system, its operation is tied into the particular PCM function that monitors the throttle position sensor (TPS). Once it feels that the driver’s foot is pushing the gas pedal all the way down (high TPS voltage), it will activate the “C” terminal to ground, thus stops the charging on those few seconds that the throttle is wide open. (Figure-6)
This type of control on later model Mitsubishi alterna-tors which have 4 regulator pins marked as G-S-L-F takes a little different from, but basically resembles
Auto Electric Corner — continued from page 4
Figure-5 Replacement Alternator Installation
Figure-6 13745 Alternator Pin ID, and the “C” Terminal
Figure-7 Mitsubishi 4-Pin Alternator and the “G” terminal
6 January 2015 APRA Global Connection
Automechanika Shanghai was held at the New International Exhibition center in Shanghai, Decem-ber 9-12, 2014. It has been three years since I last attended Automechanika Shanghai. The most impressive thing about the show is how much it has grown. Three years ago there were two long rows of pavilions reaching outward from the central entrance to form a "V". Now the top of that V has been filled in by another row of pavilions as long as the other two. Messe Frankfurt has done their best to categorize the pavilions, in some cases by country and in others by product type. However, this is proven to be a partial solution. If you are searching for a particular part category, you may find it scattered randomly in most of the pavilions. Therefore, searching for new part sources take some digging. The positive side of that is that there are a huge number of sources available. Going to and
from the exhibition is quite an adventure. Long taxi lines, long lines for tickets at the subway, and bumper-to-bumper traffic or daily occurrences. The best strategy we found was to have the taxi driver drop us off a block away in the morning and then to have dinner at the nearby shopping mall in the evening. After that picking up a taxi at the Kerry Hotel is relatively pain-free. Those of us who attend next year may have to devise a new strategy, as Automechanika will relocate to a larger venue. Yes, I said larger.
It was pleasing to see several APRA members at the exhibition selling parts into China. Another mem-ber has made progress on his plans to expand his business into China. Although it's in the beginning stages, it is clear that the Chinese are developing a domestic remanufacturing market.
Engine Core, prior to RemanufacturingRemanufactured Engine, converted to Natural Gas
Remanufactured Label
Remanufacturing Center
Two Photos of the Engine Reman Plant at Jhangjiagang.
Automechanika Shanghai 2015APRA presented four programs during the exhibi-tion. Omar Cueto of L and J Diesel gave a presenta-tion on the history and operation of the common rail fuel injector. Harry Shi, of Duxes, presented an overview of current Chinese legislation for remanu-facturing. I presented a report on the expanding Chinese market for remanufacturing and the opera-tion of the core market and reverse logistics in the United States. Tom Jackson of RAS was on hand to answer questions. We had excellent audience participation and interest.
One our last day we were invited to tour the reman-ufacturing center at Jhangjiagang (jon-gia-gong). They have a demonstration center that features the history of Chinese remanufacturing and examples of remanufactured products. Of the most impres-sive examples is a Chinese-made Yuchai (you-cheye) engine core and remanufactured engine. Not only has the engine been completely remanufactured, it has also been retrofitted to run on natural gas. Less than ½ mile away is the remanufacturing plant for the Yuchai engine. The plant is beginning its initial ramp up in production. Anticipated full pro-duction figures weren't available. Approximately 100 cores were in the building. All of them were dismantled. It will be interesting to see the plant running at or near capacity.
George Davis Technical Director
Do you have a unique business approach or marketing secret that has contributed to the success of your reman business?
Submit your article by the 15th of the month to: George Davis: [email protected]
Share yourSuccess!
7APRA Global Connection January 2015
Place a Classified Advertisement(First 50 words FREE for all APRA members) $1 per word for each additional word over 50. $3 per word for all non-members.
Write down your classified ad as you want it to appear (please type or print) and mail, fax or email it with this form and your full payment to APRA. We must receive payment BEFORE your ad is published. You may advertise equipment, parts, cores, businesses for sale, help wanted, etc.
Please be sure to check off which issue(s) you would like your ad to appear. ADDED BONUS: Your ad will appear on APRA’s website (www.apra.org) at no additional charge.
Please check ad type you are submitting:r For Sale r Business For Sale r Wanted r Help Wanted r Services/ Misc.
Which issue(s) will your ad appear in?:r October 2014 r November 2014 r December 2014 r January 2015 r February 2015
Please print or type:
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MAIL TO: APRA, Global Connection, 4460 Brookfield Corporate Dr., Suite H, Chantilly, VA 20151-1671 703-968-2772 • FAX 703-968-2878 • e-mail [email protected]
Visit APRA ONLINE: www.apra.orgWEBINAROn Market Potential January 22, 2015
Join a U.S. Commercial Service Global Automotive team hosted webinar on January 22nd to learn more about market potential in Colombia, Panama and Peru for automotive aftermarket, chemicals lubricants, components, tools and testing equipment, services and more.
Register online: https://emenuapps.ita.doc.gov
US Government Export Portal — Helps US businesses participate in the global marketplace with information on trade events, tariffs and export counseling assistance.
8 January 2015 APRA Global Connection
9APRA Global Connection January 2015
10 January 2015 APRA Global Connection
New Product Announcements
Getting a handle on complexityNew INA FEAD Kit from Schaeffler Automotive Aftermarket sets new Repair Standard
Valley City, OH / Schaeffler Group USA Inc.
The new INA FEAD KIT is now offered by Schaef-fler Automotive Aftermarket as a complete solution for repairing front-end accessory drives (FEAD). This product addresses the increasing complexity of a system supplying vital vehicle functions with ever-increasing loads. For many popular European applications, Schaeffler offers a tailor-made INA FEAD KIT. The kit contains all the wear components that need to be replaced regularly, eliminating the need to source these components individually.
Modern vehicle maintenance requires replacement of several FEAD system components, not just the belt. This is due to features such as high output alternators and start-stop systems which increase FEAD system complexity. Additionally, down-sized engines with greater torque variation and stricter emission regulations increase demands on the entire FEAD system.
“As a development partner to vehicle manufacturers, Schaeffler possesses high levels of know-how when it comes to the different components in the front-end accessory drive,” says Christian Kos, Senior Manager Category Management Engine, Schaeffler Automo-tive Aftermarket. “We have decades of experience in the independent Aftermarket that allow us to com-bine the right components for repair.
With the INA FEAD KIT, we are setting a higher standard for repairing front-end accessory drives.” The INA FEAD KIT always includes the belt, tensioner and idler pulleys, and all accessory parts needed. Depending on the application, the repair solution may also contain an overrunning alternator pulley (OAP) or water pump. For improved repair time and convenience, the kit contains the right belt routing diagram for the vehicle.
The number of vehicle manufactures specifying FEAD belt and component replacement intervals is increasing. The INA FEAD KIT from Schaeffler Automotive Aftermarket sets the new standard for the repair of front end accessory drive systems.
Schaeffler Automotive Aftermarket has been responsible for the Group’s global automotive replacement parts business for the LuK, INA and FAG brands for over 35 years from its headquar-ters in Langen, Germany. With a global network
of approximately 11,500 distribution partners and 30 sales and representative offices, the company is known for its close proximity to customers and for delivering superior service.
Schaeffler with its product brands INA, LuK and FAG is a leading global provider of rolling bearing and plain bearing solutions and of linear and direct drive technology, as well as a renowned supplier to the automotive industry of high-precision products and systems for engines, transmissions and chassis. The group of companies with operations around the world generated revenue of approximately 11.2 billion euros in 2013. With around 79,000 employees worldwide, Schaeffler is one of the largest German and European technology companies in family ownership. With approximately 170 locations in 49 countries, Schaeffler has a worldwide network of manufacturing locations, research and development facilities, sales companies, engineering offices, and training centers.
Judy Love, MarketingSchaeffler Automotive Aftermarket5370 Wegman Dr., Valley City, OH 44280Tel. 330.558.5263 / Fax 330.558.5363
Find us on Facebook: Automotive Parts Remanufacturers Association — APRA
11APRA Global Connection January 2015
12 January 2015 APRA Global Connection
be worth in excess of USD 1 trillion per annum by 2025, create 100,000 new jobs, generate USD 500 million in material cost savings and prevent 100 mil-lion tons of waste. This information is based on the sum of two reports findings involving the WEF and McKinsey. The first report was on medium-lived complex goods, the second, fast moving consumer goods. “This involved a bottom up modeling of sub-segments of medium-life complex goods and fast moving consumer goods, various levers for the
capture of end of use products and the ability to reuse, repair, remanu-facture, refurbish or recycle.” It is an estimation of the value of raw mate-rial substitution and demonstrates the mam-moth financial gain that can be made from regenerative economic flows by design, such as remanufacturing.
There are countless reasons why remanufac-turing is beneficial and has so much potential, but as Morlet points out “what’s quite intriguing
about it globally is it’s a tiny part of the economy. Yet there is a significant amount of momentum building up around the topic, so it’s encouraging.” The most comprehensive analysis of reman has been led by the USA, the world’s largest market, which estimates its value at USD 45 billion. Nonetheless, this only accounts for a mere two percent of revenue for products sold in the categories that were looked at. Companies are becoming increasingly interested in remanufacturing as the price of raw materials has rapidly increased over the last ten years; there is considerable new demand as three billion more middle class consumers are expected over the next ten to fifteen years.
Remanufacturing spans across a vast array of sec-tors, from aerospace to electronic equipment, and the number of products for which remanufactur-ing presents an opportunity is ever-increasing. The
attraction of a product of the same or better perfor-mance and quality than the original, at a fraction of the cost, is invari-ably the biggest draw of procuring remanufactured items and Morlet believes consumers will begin to see this as “very attrac-tive… the broader com-munity and customers are going to start to appreci-ate the value of reused products over and above new ones because of the fact that they can access them at lower costs.”
When I asked Andrew if he thought remanufactur-ing was central to the USD 1 trillion plus oppor-tunity in the circular economy, his response was
“absolutely”. A general evolution of thinking within business, governments and the broader community needs to be realized to understand the benefits of reman; whether it be the energy saving, reduction of greenhouse gases, all round cost savings, as well as the retention of raw materials in a world where raw materials are dwindling. Moreover, by bring-ing major companies and establishments together, educating and promoting remanufacturing and the circular economy, the Ellen MacArthur Foundation is unequivocally attracting notable attention for their progress in turning their financial projection into an economic reality.
With special thanks to Andrew Morlet.
Reman Industry Focus (RIF) is currently the only bilingual Chinese-English e-publication focused on the reman industry, owned by Duxes (Shanghai) Business Consulting Inc. For the latest issue please refer to: http://duxes.cn/enewsletter/rif/
What’s quite intriguing about [remaufacturing] globally is it’s a tiny part of the economy. Yet there is a significant amount of momentum building up around the topic, so it’s encouraging.
—Andrew Morlet
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and X-Ray equipment, and recently opened a new remanufacturing plant in the Netherlands. Another major partner, Cisco, remanufactures electronic devices including products such as routers and switches. Morlet elaborated on the extent of elec-tronic remanufacturing currently taking place, citing IBM as an example, with products including: small mainframes, larger industrial computer systems and hardware, “they are being very clever in the way they design their products, so they can be upgraded, repaired and remanufactured.”
The Foundation also offers education pro-grams to push the idea of a circular economy forward; the Disrup-tive Innovation Festival was their most recent. It brought together partici-pants from 170 different countries, including notable educational institutions and thought leaders both online and in physical venues. When the Foundation set out, it wanted to quantify the economics of the model so entered into a knowl-edge partnership with McKinsey & Company to produce the first quantitative report on the circular economy. The report looked at medium-lived com-plex goods in Europe, which is typically products with a life and use period that is more than one year and less than ten, which included small commercial vehicles. They took the report to the World Eco-nomic Forum (WEF) in 2012 and began to garner interest from global companies such as Accenture and various governments. The Foundation has continued this relationship with the WEF over the past few years, jointly conducting further reports in collaboration with the WEF and McKinsey.
Project MainStream, is a joint initiative of these three parties and, in part, explores “asset track-ing”, a way of being able to monitor and locate products as they move across global supply chains, enabling the recovery of materials and components. Con-sequently, this makes it easier to remanufacture these parts in the long term as they move from the original owner to sub-sequent owners or lessees of the products. This has obvious benefits for core (used component) collec-tion, which is at the heart of the remanufacturing business.
In particular, the Ellen MacArthur Foundation has attracted a lot of attention with its economic analy-sis highlighting that the circular economy could
Morlay Interview — continued from page 1
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Remanufacturing in particular is “one area significantly underutilized internationally and we are very keen to promote remanufacturing, refur-bishment, product service systems and business mod-els that allow companies to get their products back at the end of use.
—Andrew Morlet
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Heavy Duty Remanufacturers Group Members are reminded to cast your ballot submit nominations for the
Heavy Duty Remanufacturer of the year!
Suggestions due December 31st!!
Mail your suggestion to: Gary Phillips HDRG Chairman 4460 Brookfield Corporate Dr. Chantilly, VA 20151-1671
ited. Use a toothpick or a piece of wire with a notch filed in it near the end resembling- a crochet hook. The lubrication of the HK Magneto and particularly the circuit breaker must be limited to one drop at one place. Lubricate the cam roller wicking No. 68 once every ten days with one drop of oil. Lubricate the screw near 110 with one drop of oil every ten days. Wipe excess oil away immediately. KEEP THE CIRCUIT BREAKER SCRUPULOUSLY CLEAN OF EXCESS OIL and keep the points adjusted to break 1/64 of an inch and most magneto troubles will be eliminated. Never use cylinder oil to lubricate any part of the magneto.
Apply one drop of oil to each bearing once every fifteen days.
Circuit Breaker Troubles
178 — The insulating washers on lower contact bar No. 191 may be broken by forcing the screws in too far. If broken, new ones must be put in before mag-neto will operate successfully, if at all.
Excess oil will ground the primary current on No. 191, also causes platinum points to burn up rapidly. Use light oil and wipe excess away immediately. Nut No. 79 must always be firmly seated. This usu-ally can be tightened sufficiently with the fingers. The circuit breaker cover No. 95 is an insulating material and oil and dirt on the outside of the circuit breaker can short- circuit it. Keep the out-side of the circuit breaker clean and free from oil. Circuit breaker cover No. 95 must never be broken or checked.
Spring No. 189 must always make good contact. Separate platinum points for breaker bar and adjust-ing screw are not sold, as they are difficult to install correctly. Complete breaker bars or adjusting screws are sold at a price as low as the cost of putting in and correctly mounting a new point.
The Distributor
179 The upper half of Fig. 23 shows a view of the dis-tributor. Unscrew nut No. 55, remove high tension bridge No. 100, remove cap, which gives view of distributor and brush "B." The carbon brush may be removed and scraped if it has a hard, irregular glaze on the surface that distributes the cur-rent to the contacts. Occasionally a brush may be worn and carbon dust will be worn off and in falling to the bottom will short-circuit cylinders Nos. 1 and 4. The distributor should be wiped with a clean cloth saturated with gasoline when required. After the magneto has been in service a long time, the face of the distributor may become rough. Dressing the surface lightly with 000 sandpaper is all that will be required.
removing spider No. 1. Beyond this point no one but a magneto expert should venture. The inside of the magneto is not complicated. NINETY- FIVE PER CENT OF ALL TROUBLE WITH THE K-W CAN BE REMEDIED AT THE CIRCUIT BREAKER OR DISTRIBUTOR. Fig. 22 shows a view of the circuit breaker. The breaker bar No. 190 is the moving ele-ment in the circuit breaker, being actuated by the cam No. 67 and the roller No. 68. This breaker bar is "grounded" to the magneto. Part No. 191, lower contact bar, and adjusting screw No. 194 comprises the second part of the circuit breaker. The lower contact bar and adjusting screw No. 191carries the primary current and is insulated from the rest of the magneto by fibre washers, bushings and plate and it is necessary that the insulation never be destroyed, nor must it be short-circuited with oil, either inside or outside of the circuit breaker.
Adjusting Circuit Breaker Points
176 — When the points between breaker bar No. 190 and adjusting screw No. 194 fail to separate, one of two things has happened. Adjusting screw No. 194 has been inserted too far and holds breaker arm No. 190 off the cam No. 68, or else the screw located near No. 110 has been made to fit too tight with a screw driver. The breaker points should always meet square. The correct separation of the breaker points is one sixty-fourth of an inch. A gauge is provided with every magneto and the separation of the points must always be tested and not guessed at. Be sure that the spring tension on the breaker arm is good and that the points come together in a snappy manner.
Be sure lock nut on part No. 190 (platinum point screw) is set tight and is free from metallic contact with breaker box or breaker box housing. This is important.
Lubrication of Circuit Breaker and Bearings
177 — The lubrication of the circuit breaker is essential, but over-lubrication must be avoided. All parts of the magneto must be lubricated with a light oil like 3-in-i or Household Lubricant. The use of an oil can to lubricate the circuit breaker or any part of the magneto should absolutely be prohib-
Magnetos[Editor's Note: A recent post on Reman Forums, "How times have changed." discussed the replace-ment of the "roll-around battery". (For those who aren't familiar with the term, most electrical shops kept a large battery mounted on hand truck, with jumper cables permanently attached, specifically for jump-starting vehicles. Our shop had a dedi-cated charger for the roll-around. Of course the battery gassed, spewing everything around it with acid, and because of its weight, was a general nuisance to take to the front lot (which had stairs), when cars needed a jump start there.) It seems the small Lithium-Ion Power Pack is taking over the duties of the roll around. Lightweight, com-pact, and, best of all, "dry" it really seems too good to be true. However, compare the modern carefree ignition system to the complexities of the magneto. Obviously, the magneto required much more service. Particularly, lubricating the cam every 10 days.
This is an excerpt from Care and Operation of the Caterpillar 45 Tractor by Holt Manufacturing Com-pany, Copyright 1917. Scanned by Google Books.]
174 —Two different types of K-W High Tension Magnetos have been used on the "Caterpillar" 45, the model TK and model HK. The model TK is described briefly in the following, but a complete discussion and price list is contained in Service Bulletin E.
HK K-W High Tension Magneto
175 — Service Bulletin C Revised contains a complete discussion of the Model HK K-W High Tension Magneto. Service Bulletin E contains a complete discussion of the Model TK K-W High Tension Magneto, and but a brief discussion will be given here.
Fig. 21 shows a longitudinal sectional elevation of Model HK. Study it instead of taking your magneto to pieces. The HK K-W Magneto is so designed that by the removal of one spring, shown at Part 29 in Fig. 21, the circuit breaker can be removed from the magneto. Remove cover nut No. 79. This allows removal of circuit breaker cap and gives access to breaker parts. To gain access to distributor, remove high tension spring No. 100, loosen nut No. 55,
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