Innovative fuel injection reduces emissions

Stricter emissions legislation mean that new engine technology and integrated drivetrain systems are being developed

With the Tier 3/Stage IIIA emissions legislation now in place in North America and Europe, the major engine manufacturers already have an array of solutions on the market. The coming Tier 4 interim/Stage IIIB legislation will be tougher still and most firms are well in hand with their plans to use both in-cylinder and exhaust after-treatment technology. While engines themselves are staying broadly similar in size, the after-treatment technologies do take up room in the engine bay and firms have had to pay close attention so as not to spoil sightlines from machines. The specialist engine manufacturers have also had to ensure that their power solutions can be installed across a wide range of machine types, while companies like 178 Caterpillar, 257 John Deere, 5895 New Holland and 2394 Volvo have been able to ensure their in-house engine development matches demands from the equipment sector. The latest off-highway machines will also benefit from more sophisticated drivelines that have been integrated into the powertrain to provide a more efficient package with lower emissions as well as fuel consumption.

Engines

196 Cummins is unveiling the first of its Tier 4 interim/Stage IIIB emissions compliant diesels in the shape of its QSL9. This engine replaces the previous QSC8.3 and QSL9 engines as the firm has decided to merge these into a single diesel, although it is available in an array of specifications to suit all installation and duty cycles. The integrated air-intake to exhaust after-treatment system uses exhaust gas recirculation (EGR) to minimise exhaust emissions. The 8.9litre engine can offer power outputs of 170-283kW, while fuel consumption has been reduced by 5%. The new engine features a sophisticated XPI extra high pressure injection system, which is able to supply multiple fuel pulses into the cylinders during each stroke. In addition a variable geometry turbocharger with a sliding nozzle delivers varying air-flow boost levels as required by the engine load and speed.
The novel air filtration system is smaller than conventional units while retaining the same performance. The low emissions technology also uses the same configuration as the Tier 4 interim/StageIIIB version of the QSB6.7 engine introduced last year. The EGR system is said to cut emissions of oxides of nitrogen by 45%. The particulate filter cuts 90% of particulate emissions and is around the same size as a conventional muffler.

German firm 201 Deutz is relying on its exhaust after-treatment (EAT) and Deutz variable emission reduction technology (DVERT) systems to ensure that its new engines meet the Tier 4 interim/Stage IIIB requirements. The company is complementing its proven Tier 3/Stage IIIA in-cylinder systems such as four-valve heads, common-rail fuel deliver, electronic controls and exhaust gas recirculation with additional exhaust gas after-treatment components. These include catalysts, particle filters and regeneration burners, urea injection SCR systems as well as electronic controls.

299 Perkins Engines says that its new 1200 Series range will meet the Tier 4 interim/Stage IIIB and offers power outputs up to 225kW from the top-of-the-line, seven litre 1206E-E70TTA. Twin turbochargers allow a 21% increase in power over the firm's previous 5.5 litre offering. The two turbochargers are mounted in series and different in size, with the smaller first stage turbo accelerating quickly giving sharp response and high torque at low engine speeds. The larger second stage turbo allows the high airflow needed to provide high power density. For outputs of less than 130kW, there are a short stroke, 6.6litre engine 1206E-66TA and the four-cylinder 1204E-E44TA/TTA, which replaces the 1104 series.

759 Scania's latest engine management and emission control developments are said to provide performance and fuel economy and new engines from the firm include the DC9, 9.3litre inline 5; DC13, 12.7-litre inline 6; and the DC16, 16.4-litre V8. Interestingly, the new common-rail fuel injection system, Scania XPI, has been developed jointly with Cummins. Key characteristics of the new industrial off-road engine range include: revised bore and stroke for increased swept volume; increased combustion pressure; easy-to-service Scania architecture with individual cylinder heads; Scania engine management; waste-gate turbocharger; Scania SCR (Selective Catalytic Reduction) exhaust after-treatment; and scraper ring to prevent coke build-up on top of the piston.

Drivelines Drivetrain

specialist Dana continues to develop advanced powertrain solutions and has developed a new version of its successful 110 axle to suit use on compact wheeled loaders weighing up to 4tonnes. The new wheeled loader driveline features a modular axle design can be used in any compact wheeled loader. According to 2254 Dana this configuration offers a good solution for compact wheeled loaders as it offers high performance and reliability as well as a cost-effective solution for customers. The brake is compact in design and the transfer box has been integrated with the rear axle to allow easy installation. A wide range of options and features are available and this model can also be specified with wet disc service brakes for higher speed models, while customers can select either a standard differential or one with a limited slip control.

The firm has also used technology from the telescopic handler market to improve drivability for wheeled excavator operators. The firm is producing a wheeled excavator driveline, suitable for machines in the 15.5-17.5tonne class, which uses a Spicer 369 shift-on-fly hydrostatic transmission and a Spicer Life 55 driveshaft. The transmission allows the operator to shift from low to high range while the machine is moving. Traditionally wheeled excavators have had to stop to shift between ranges.
The Spicer 369 transmission is directly connected to a 163LD rear axle, while drive at the front is provided by a model 263LD drive and steer axle.

Meanwhile rival firm 2304 ZF says it has new driveline solutions including products for the wheeled loader and ADT markets as well as a steering system for telehandlers. Efficiency is the key and ZF is offering new transmissions for wheeled loaders that boost operating efficiency and help cut running costs. The five speed Ergopower transmission comes with a lock-up clutch, axle disconnect and a differential lock-up controlled by intelligent software so it optimises performance.
The firm has also developed a new Ergopower L2 transmission that is designed for use in ADTs and offers eight forward speeds as well as four reverse ratios. Designed for machines with payloads of up to 45tonnes, this helps reduce fuel consumption. However the main benefits include ensuring smoother shifting between ratios that help extend component wear life as well as providing a better match of ratios to the running conditions and a retardation system on the input side that increases retardation efficiency.