Fpt Industrial - Tier 4

7/30/2019 Fpt Industrial - Tier 4

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INDUSTRIAL RANGE

FOR CONSTRUCTION APPLICATIONS.

THE STRENGTH OF INNOVATION.

TIER 4 INTERIM/STAGE IIIB.





Clean Power.

During the combustion process inside an engine, the chemical energy is transformed into amechanical one. Due to the impurity of fossil fuel during the combustion process, several toxicsubstances are produced. They are primarily NOx, CO, HC, PM.

• NOx: Nitrogen Oxides are the main cause of acid rain and ozone layer reduction. At high combustiontemperatures, usually above 1600°C, molecular nitrogen (N

2) and oxygen (O

2) disassociate into their

atomic states and react producing NOx.

• CO: Carbon Monoxide is a poisonous gas, tasteless and odourless. It develops during combustion inpresence of low oxygen concentration (rich blends) or when the oxygen is not uniformly distributed.CO emission for Diesel engines are low.

• HC: Hydrocarbons are composed by organic elements - contained both in the fuel and in the oil -and produced by incomplete combustion. The HC amount increases together with the fuel volumein the combustion chamber.

• PM: Particulate Matter is mainly composed by minute carbon particles and other toxic substancescreated during incomplete fuel burning process i.e. low combustion temperature. The effects ofinhaling particulate matter have been widely studied in humans and animals and include asthma,

lung cancer and cardiovascular issues.



Being the most critical pollutants, NOx and PM have been both reduced by approximately 60% since 1996.In the next few years a further step of approximately 90% reduction of NOx and PM will be achieved.



Making a cleaner environment.

Both in the US and Europe many efforts have been carried out to make Diesel engines as clean aspossible. Engines must be environmentally friendly during their entire life period and under a widerange of operating conditions.Starting from 2011, Tier 4 interim/Stage IIIB regulations will firstly concern engines with power above130kW to be then extended to other power ranges.Tier 4 interim/Stage IIIB compliance implies a significant reduction of both NOx (-50%) and PM (-90%)over today’s Tier 3/Stage IIIA levels.



Emissions Standards.Non-road engines for mobile, construction and forestry machineries (Europe and US).

Emission Limits Stage IIIA/Tier 3(1) Stage IIIB/Tier 4 interim Stage IV/Tier 4

(g/kWh) NOx HC(2) CO PM NOx HC(2) CO PM NOx HC(2) CO PM

130 ≤ P ≤ 560 kW 4.0 3.5 0.20 2.0 0.19 3.5 0.02(3) 0.4 0.19 3.5 0.02(3)

56 ≤ P < 130 kW 4.0 3.5 0.20 3.4(4) 0.19 5.0 0.02(3) 0.4 0.19 5.0 0.02(3)

P < 56 kW 4.7 5.0 0.40 4.7 5.0 0.30(5) 4.7 5.0 0.03(3)

2008« »2009 2010 2011 2012 2013 2014 2015 2016

130 ≤ P ≤ 560 kW

56 ≤ P < 130 kW

19 ≤ P < 56 kW

LEGEND

(1) Only worst case (lower) limits reported(higher limits available for limited powerbands in USA and for CO and PM in Europe)

(2) NMHC considered for US Tier Limits

(3) EU Stage IIIB and Stage IV PM limit is 0.025(4) EU Stage IIIB NOx limit is 3.3(5) EU Stage IIIB PM limit is 0.40

LEGEND

Stage IV introduction date is 1st September 2014 , while Tier 4 is 1st January 2015.

Tier 3/Stage IIIA

Tier 3/Stage IIIA

Tier 3/Stage IIIA

Tier 4 interim/Stage IIIB



Tier 4/Stage IV

Tier 4/Stage IV

Tier 4/Stage IV



The environment request:simultaneous reduction of NOx and PM.

FPT Industrial answer: SCR technology

Due to the opposite reaction to combustion temperature, the reduction of either of the combustionproducts (NOx or PM) necessarily implies the increase of the other one.

In order to simultaneously reduce either NOx and PM, as required by Tier 4 interim/Stage IIIB, itis necessary to work on different combustion management and exhaust gas treatment systems.

SCR (Selective Catalyst Reduction) technology is an after-treatment system that transforms theNOx produced during the higher temperature combustion process into Nitrogen (N

2) and

Water (H2O), both of which are naturally occurring “chemicals” in the atmosphere.

Thus the use of the SCR system allows PM reduction, optimizing at the same time combustionprocess and engine performance, whereas NOx reduction occurs downstream of the engine.

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The addition of the SCR system to engine confi gurationallows exhaust emissions to comply withTier 4 interim/Stage IIIB emission level in two simple steps.


The high temperaturecombustion engine

calibration producesNOx and a very

limited amount of PM.

1SCR

after-treatmentreduces NOx.

Independently ofthe combustion

process.

2



SCR system: how it works.

The SCR (Selective Catalyst Reduction) after-treatment system adopts a catalyst converting NOxinto Nitrogen (N

2) and Water (H

2O) thanks to the chemical reaction with a Water-Urea solution

(DEF: Diesel Exhaust/Emission Fluid).The Water-Urea solution is a non toxic, colourless and odourless mixture of chemical urea anddemineralised water.The whole system is controlled and managed by the Dosing Control Unit (DCU) inside the SupplyModule.

The main components of the SCR system are:• Supply Module• DEF Tank• Dosing Module• SCR Catalyst

During the engine start up, the DCU performs the after-treatment system check. In the next step theWater-Urea solution is introduced into the exhaust pipe by means of a specific injector (Dosing Module),producing steam and ammonia (NH

3) (hydrolysis).

In a second step, the SCR Catalyst reaction gives out nitrogen and water substances, innocuous forthe environment.

When switching off the engine, the Water-Urea solution is completely purged into the tank.

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Supply module

DEF Tank

Dosing module

SCR catalyst



SCR main components.

Supply module: is the unit thatpressurizes and pumps Water-Ureasolution. It is made up of a DCU

and Water-Urea solutionpump. The DCU controlsand managesWater-Urea solutionin quantity and pressurevia temperature andpressure sensors. TheWater-Urea solution pumpconveys the pressurized fluidto the dedicated dosing Module.

Dosing module: is the unitresponsible for the injection ofWater-Urea solution inside theSCR Catalyst. It is managed

by the supply module.

DEF Tank: is the storage placeof Water-Urea solution on thevehicle. It contains fluid

temperature and levelsensors.

SCR Catalyst: is the part of the systemwhere chemicalreduction takes place.

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System Integration.

The SCR system is engineered to allow simple installation and flexible positioning giving theOEM the possibility to keep the same vehicle architecture as Tier 3/Stage IIIA.The specific design of all the system components makes them easily accessible in termsof maintenance and refilling operations (see picture below).

Supply moduleDEF Tank

SCR Catalyst

Dosing moduleEngine



The NEF series.

Developed to satisf y the most demanding customers’ requirements, the NEF Series is the evidenceof FPT Industrial technological excellence. Both 4 and 6 cylinder configurations are equipped witha second generation heavy duty Common Rail injection system, allowing to achieve topperformance in terms of load response, maximum torque and top power with the minimumfuel consumption. The NEF Series also stands out for its great flexibility and reliability,thus representing the reference in its category.

LEGEND

ARRANGEMENT AIR INTAKE INJECTION SYSTEML: In-line TAA: Turbocharged After Cooled ECR: Electronic Common Rail

MODEL

CYLINDERS

ARRANGEMENT

AIR FEEDING

INJ.

SYSTEM

DISPL.

(LITRES)

POWER TORQUE DIMENSIONS

KW (HP) @ RPM NM KGM RPML

(MM)

W

(MM)

H

(MM)

N45 ENT 4L / TAA ECR 4,5 75 102 2200 472 48 1400 833 685 955

N45 ENT 4L / TAA ECR 4,5 89 121 2200 549 56 1500 833 685 955

N45 ENT 4L / TAA ECR 4,5 110 150 2200 676 69 1500 833 685 955

N45 ENT 4L / TAA ECR 4,5 125 170 2200 700 71 1500 833 685 955

N67 ENT 6L / TAA ECR 6,7 129 175 2200 810 83 1500 1062 681 1018

N67 ENT 6L / TAA ECR 6,7 151 205 2200 960 98 1500 1062 681 1018

N67 ENT 6L / TAA ECR 6,7 181 246 2200 1120 114 1500 1062 681 1018

N67 ENT 6L / TAA ECR 6,7 210 286 2200 1143 117 1500 1062 681 1018



FEATURES

Injection system

State-of-the-art system for accurate fuel delivery, based on a very compact direct injection 2ndgeneration Common Rail (1.600 bar) to achieve top performance in terms of load response, maxtorque and top power with the minimum fuel consumption.

Engine design

Multiple injections, balancer counterweights incorporated in crankshaft webs, rear geartrain layout,camshaft in crankcase, suspended oil pan, ladder frame cylinder block and, for 4 cylinder engines,countershafts arrangements available as options.

Components integration

Integrated CCV (Closed Crankcase Ventilation) system and engine design oriented to high componentsintegration. Water-oil cooler, oil and water pumps are completely integrated in the engine block.

Specific features

Engine specifically designed for industrial applications; lean layout; starting temperature withoutauxiliaries down to -15°C (with grid heater down to -25°C, with water and oil heater down to -30°C);engine slope up to 35° continuous angle in all allowable directions. Tier 4i/StageIIIB exhaustemissions compliance achieved with SCR, but without external EGR and VGT. Power densityincrease related to Tier3 version of 17%.

Air handling

NEF series engines are turbocharged with Air to Air intercooler. The above described features allow OEMcustomers to optimize engine installation, machine performance, load response and fuel consumption.

600h oil interval change

NEF series adopts combustion chambers and high pressure injection system optimized to reduceoil dilution. Design is optimized in terms of mechanical clearances, piston rings and oil systemcalculation.

Serviceability & maintainability

Worldwide service network including over 1500 service points. Engine ECU (Electronic ControlUnit) with CAN-BUS control & monitoring interfaces can be used for advanced real time diagnosis.

Option list

Availability of a wide range of options for transmissions, alternators, radiators, air filters, mufflers,oil pans, SAE standard transmission interfaces, PTO SAE A-B and air conditioning compressorarrangements. Specific options may be developed on demand. Double confi guration for SCR catalyst(vertical and horizontal) for both 4 and 6 cylinder; specifi c AdBlue/DEF tank for each engine.

BENEFITS

FLAT TORQUE AND HIGH ENGINETHERMODYNAMICPERFORMANCE WITH LOWFUEL CONSUMPTION.

VIBRATION & NOISE REDUCTION.

LEAKAGE PREVENTION.

HIGH PERFORMANCEGUARANTEED IN ALLCONDITIONS.

HIGH ENGINE POWER DENSITYAND FAST LOAD RESPONSETIME WITH THE LOWEST FUELCONSUMPTION.

REDUCED MAINTENANCENEEDS AND OPERATING COST.

QUICK SERVICE SUPPORTAND FAST MAINTENANCEACTIVITIES.

CUSTOMER ORIENTATIONAND SPECIFIC ENGINEARCHITECTURE BASEDON APPLICATION TYPE.



The CURSOR series.

The CURSOR Series is the right choice for customers requiring top power, fast load response, highpower density together with the lowest fuel consumption.Featured by outstanding performance, this series is dedicated to heavy duty applications from 245to 407 kW. Superb performance is just one of the benefits of these engines: high reliability, longmaintenance intervals, which means extremely low operating cost, are the core values of the range.Thanks to continuous research and development activities, the CURSOR Series adopts the most ad-vanced technologies, such as the C87 second generation heavy duty Common Rail injection system.

LEGEND

ARRANGEMENT AIR INTAKE INJECTION SYSTEML: In-line TAA: Turbocharged After Cooled ECR: Electronic Common Rail

EUI: Electronic Unit Injector

MODEL

CYLINDERS

ARRANGEMENT

AIR FEEDING

INJ.

SYSTEM

DISPL.

(LITRES)

POWER TORQUE DIMENSIONS

KW (HP) @ RPM NM KGM RPML

(MM)

W

(MM)

H

(MM)

C87 ENT 6L / TAA ECR 8,7 245 333 2150 1430 146 1100 1253 858 1008

C87 ENT 6L / TAA ECR 8,7 269 366 2150 1540 157 1100 1253 858 1008

C87 ENT 6L / TAA ECR 8,7 295 401 2150 1640 167 1300 1253 858 1008

C13 ENT 6L / TAA EUI 12,9 332 450 2100 1924 196 1400 1357 900 1148

C13 ENT 6L / TAA EUI 12,9 369 500 2100 2161 221 1400 1357 900 1148

C13 ENT 6L / TAA EUI 12,9 407 550 2100 2400 245 1400 1357 900 1148



FEATURES

Injection system

Direct injection fuel system, state-of-the-art systems for high precision in fuel quantity injection inorder to achieve top performance in terms of load response, torque and top power with the minimumfuel consumption:• C87: featuring very compact 2nd generation Common Rail System• C13: featuring electronically controlled unit injectors

Engine design

Super finished helical timing gears, precise control of fuel injection system, with pilot fuel injectionpulse, bed-plate in addition to engine block, crankshaft with net shape counterweights, rear geartrainlayout and suspended oil pan.

Components integration

Improved technical solutions in order to achieve high components integration such as integrated patentedCCV (Crank Case Ventilation), integrated oil cooler, integrated oil pump and integrated water pump.

Specific featuresFunctional lean layout; starting temperature without auxiliaries down to -15°C (with grid heater downto -25°C); high engine inclination up to 35° continuous angle in all directions with secondary oil pump.Tier 4i/StageIIIB exhaust emissions compliance achieved with SCR, but without external EGR and VGT.Power density increase related to Tier3 of 12%.

Air handling

Waste Gate Turbocharged with air-to-air charge cooled air system with 4 valves per cylinder toincrease engine efficiency by the optimization of thermodynamic performance in terms of time totorque, load response and reduced fuel consumption.

600h oil interval change

Optimum engine design in terms of mechanical clearances, piston rings, engine oil system calculation.

Serviceability & maintainability

Worldwide service network including over 1500 service points. Enhanced engine serviceability anddiagnosis by using the Electronic Control Unit on the engine with CAN-BUS control & monitoringsystems interface.

Option list

SAE1 as standard transmission interface; two possible PTO arrangements (SAE-A, B flange 9 or 13 teeth)up to 200Nm torque availability; air conditioning compressor arrangement; turbocharger in low position.Double configuration for SCR catalyst (vertical and horizontal) for C9; specific AdBlue/DEF tank for each

engine.

BENEFITS

HIGH ENGINE THERMODYNAMICPERFORMANCE WITH LOWFUEL CONSUMPTION &SMOKE REDUCTION DURINGTHE TRANSIENT.

VIBRATION & NOISE REDUCTION.

LEAKAGE PREVENTION.

HIGH PERFORMANCEGUARANTEED IN ALLCONDITIONS.

HIGH ENGINE POWER DENSITYWITH THE SHORTESTLOAD RESPONSE TIME.

REDUCED MAINTENANCE

NEEDS AND OPERATING COST.

QUICK SERVICE SUPPORT.

CUSTOMER ORIENTATION.



10 reasons for choosing SCR.

1) OUTSTANDING PERFORMANCE: as SCR is an after-treatment system, the engine isdesigned to maximize torque and power with the shortest load response time.

2) HIGH RELIABILITY: the SCR system allows the engine to reduce heat rejection of

many internal engine components which leads to better reliability.

3) LOWER FUEL CONSUMPTION: the efficiency of the combustion process optimizesfuel consumption reducing customer running costs.

4) LONGER SERVICE INTERVAL: the optimized combustion process preserves oilphysical properties reducing maintenance activities and related downtime.

5) COMPACT PACKAGING: compared to Tier 3/Stage IIIA engine, the thermodynamicefficiency of SCR system allows to downsize displacement enhancing performance.

6) WIDE FUEL COMPATIBILITY: the SCR system works regardless fuel quality. In the

FPT Industrial SCR technology the catalyst substrates are not influenced by the presence oftraditional poisoning substances in the fuel, such as sulphur.

7) UNBEATABLE DURABILITY: the SCR system is engineered for life! The reduction ofPM inside the engine grants total absence of clogging problems and excludes any regenerationintervention.

8) USER FRIENDLY SOLUTION: the SCR system is simple! The only thing to do is refillingDEF when the level indicator flashes in the vehicle instrument cluster.

9) ADVANCED TECHNOLOGY: the SCR is recognized by most of the engine manufacturersas the technology of the future to be compliant with Tier 4 final/Stage IV.

10) ENVIRONMENTAL CARE: using the SCR system, pollutants produced during thecombustion process are converted into harmless N

2and H

20, already present in the environment.

SCRBENEFITS





Questions & Answers.

What is the driver of FPT Industrialstrategy to achieveTier 4 interim/Stage IIIB emissions?

How does SCR achievethe emission target?

Which advantagesdoes the SCR technology offer?

FPT Industrial has chosen to focus on customer’s productivity andoperating costs optimization, recognizing SCR as the best solution formedium & heavy duty engines. SCR allows to reduce the high operatingcosts by working on fuel consumption and maintenance intervals (oilchange).

With the SCR technology gas reduction is completely managed by the

after-treatment system outside the engine, which is thus capable ofperforming optimal combustion with lower fuel consumption.

There are at least 10 valuable reasons by which SCR is the mostconvenient choice:

• Outstanding Performance• High Reliability• Lower Fuel consumption• Longer Service interval• Compact packaging• Wide Fuel Compatibility• Unbeatable Durability• User friendly solution• Advanced technology• Environmental care



Where will the SCR be commercialized?

Will DEF (Diesel Emission Fluid)be distributed also in the USA?

Is there any critical issue regarding SCRintroduction in the USA?

What does it happen if DEF Tank is empty?

Is the SCR system affected by lowtemperatures?

Has SCR installation constraints?

SCR will be commercialized in all the countries where theemission regulations will require Tier 4 interim/Stage IIIBstandards.

Yes.

No, because since 2010 the DEF distribution network has beendeveloped in the USA (many American engine’s manufacturers

will adopt SCR for EPA10 on road compliances).

A led on the vehicle’s cluster will switch on and after a period oftime the engine will be switched in limp home-mode to preservethe safety.

No, FPT Industrial SCR system perfectly works at low temperature.Even in case of cold start with frozen urea solution (temperaturebelow -11°C/12°F) the engine works properly without any derating.

OEM’s have to respect FPT Industrial SCR installation guidelines,

however the system is engineered in order to be easy to install, withflexibility in terms of length of pipes & height positioning, and FPTIndustrial will provide full support to ensure the final installationcomplies with the emission legislation.



At your service everywhere.

Sales and Services.

FPT Industrial counts on a worldwide organization including over 1500 sale & service points able toassist Customers in their purchase and to provide them with engine maintenance and parts. Thanks to frequent training courses, FPT Industrial network will be pleased to assist you wherever andwhenever necessary, supplying only original parts of proven quality.





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Via Puglia 15, 10156 - Torino, ItalyEmail: [email protected] - www.fptindustrial.com

FPT Industrial S.p.A.

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Fpt Industrial - Tier 4