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

Market Specification Development Criteria

15 StandardEngine Development

Criteria

Marketability, Aesthetics

Durability Requirements

Cost, Size, Weight Constraints

Required Horsepower,Torque, PTO Loads

Engine Controls, Governoring, Speed

Fuel Systems and Carburetion

Exhaust Systems

Engine Configuration,Space Limitations

Parasitic Starting Loads,Inertia Requirements

Cycle Time of Operation,Charging Systems

Operating Environment

Cooling Management

Vibration Systems

Maintenance Related Accessories

Safety of Operation

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

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

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.

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.

4 quart tanks

metal plastic

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

Walk Mower Tank Geometry

Investment -- One ExampleGas Tanks for Intek Engines• Three different fuel tank configurations to accommodate

OEMs/applications• 10 molds • Millions of dollars of toolingShrouds• 4 Shroud/Styling Packages for one engine

– 4 Tools @ $110,000 per ToolFuel caps• Five Different Fuel Caps Used in Production for one

engine• Total of 32 Cavities