The Art of Creating Energy

The quest to control, command and power is a process that takes decades of development, searching out strength and smarts, developing skill and talent, applying force and drive and finally engineering inventions that are efficient and reliable energy creators. When it comes to creating mechanical energy — the power to operate our machines — it’s a tradition associated with icons like Perkins, Yanmar, Honda, Cummins, Kubota, John Deere and many, many others.

The journey to find the ideal engines is also a time-honoured tradition of Compact Equipment. Working with the biggest names in the small engine industry, we’ve compiled a compendium of brands and product information over the years for our readers to review and process. While engine choices are not really commonplace when picking an actual machine (if you choose a Bobcat skid steer, you’re pretty much getting a Kubota engine), being confident in the OEM power plant of a certain brand can be a deal breaker for gear heads who know and buy equipment.

Over the next nine pages, we have assembled an anthology of all things engines — product information, brand history, technology summaries, emission explanations and more — to help our readers better understand these gas and diesel power plants. Peruse them at your convenience, beginning here with England’s famous trademark Perkins.

To help us better understand how quality engines are created, Perkins Engines (today a subsidiary of Caterpillar) invited CE to visit its corporate headquarters in Peterborough late last year, as it launched its next-generation of engines that comply with ever-increasing emission regulations and meet the ever-increasing demands of its consumers. Perkins engines power machine models in the construction, landscape, marine, industrial and agriculture sectors. There’s a saying that states one in five tractors worldwide is powered by a Perkins engine.

From humble beginnings in Peterborough, Cambridgeshire, England, in 1932, Frank Perkins’ engine company has grown to become a leading supplier of diesel and gas engines. Ranging from 5 to over 2,600 hp, Perkins power plants command over 5,000 different applications from over 1,000 major equipment manufacturers.

“For Perkins, product range is not just about providing an engine of a specific power, but of offering customers a choice of engine configurations and options,” says Oliver Lythgoe, Perkins Tier 4 marketing manager.

Perkins’ latest range to be launched — the 1200 Series — will build on the strengths of the current, popular 1100D Series of engines. At the top of the range is a 7-litre, six-cylinder engine, capable of 225 kW (300 hp), and potentially even higher in some special applications.

“This represents a 21 percent increase in power output over Perkins current 6.6-litre offering, giving customers who may have chosen a larger engine previously, the choice of the same power from a smaller engine package,” says Allister Dennis, Perkins product marketing manager.

As part of the range development Perkins has introduced a number of new features to reduce service requirements. The poly-vee, front-end auxiliary drive has a service interval of twice that of the current system on the 1100 Series range. Hydraulic tappet adjustment has been added which avoids the need to check and adjust valve clearance at 1,000 hour intervals, thus saving time and expense for the machine owner. It will also allow machine designers to make better use of the space directly above the engine for mounting other equipment, such as after treatment.

“Though the after treatment is typically positioned above the engine, it can in fact be mounted pretty much anywhere on the machine,” says Lythgoe. “After treatment will be offered both as an independent canister [non-modular], but also as a tightly packaged module, thus saving engineering and validation effort for OEM customers.”

Whilst the diesel particulate filter will remove nearly all of the particulates from the exhaust stream, it is still desirable to have very low particulates out of the engine. To achieve this, Perkins is using electronically controlled high pressure common rail fuel systems. All of these engines will employ Perkins NOx reduction technology, rather than SCR technology so there will be no requirement for the customer to buy, store and fill up with urea (see more about the SCR/EGR debate on page 30).

Advances have also been made with the 800 Series engines. Power and torque is being increased, by up to 40 percent, allowing an engine choice for customers who might currently take the lower range of the 1104D engine. With its more compact package, it will allow OEMs to make some room for the after treatment packaging and will provide better fuel economy in some operating conditions. The 400 Series completes the compact range lineup. Although this range already meets Tier 4 Interim, the legislation for NOx and particulates do not currently require after treatment and these engines are already in customer machines.

Keith Gribbins is managing editor of Compact Equipment, based in Peninsula, Ohio.

John Deere Power Systems

Offering Innovative Compact Interim Tier 4-Compliant Diesel Engines

The Company

John Deere Power Systems (JDPS) is a leading producer of off-highway diesel engines, supplying heavy-duty engines and drivetrain components for John Deere equipment and OEM applications. JDPS designs and manufactures a variety of OEM components, including: industrial generator-drive, marine and mining diesel engines; axles; transmissions; pump drives; and planetary drives. John Deere first entered the engine business in 1918 when it purchased Waterloo Gasoline Engine Co. In 1949, Deere produced its first diesel engine.

Innovative Compact Engine Lineup

The Interim Tier 4 (IT4)-certified PowerTech M and PowerTech E 2.4L models are the latest addition to the John Deere lineup of compact engines. Two ratings of the PowerTech M 2.4L are IT4 certified, and these models are ideal for lower horsepower applications such as compact equipment. Their simple design and mechanical controls give OEMs and end-users additional flexibility and cost savings while maintaining the same engine platform as Tier 2 engines. PowerTech M 2.4L engines feature two-valve cylinder heads, fixed-geometry turbochargers, self-adjusting poly-vee fan drives, a mechanical unit pump fuel system, 500-hour oil changes and turbocharged aspiration. The power range on these models is 48 to 49 hp (36 to 37 kW).

Additionally, four new ratings of the PowerTech E 2.4L engine are IT4 compliant. PowerTech E engines are also ideal for compact equipment and offer a new electronically controlled unit pump fuel system with improved cold-start performance, precise engine speed control, torque curve shaping and more. These engines feature full-authority electronic engine controls, two-valve cylinder heads, fixed-geometry turbochargers, self-adjusting poly-vee fan drives, 500-hour oil change intervals and air-to-air-aftercooled aspiration. The power range on these models is 60 to 66 hp (45 to 49 kW).

Other engines from the John Deere lineup that are suited for compact equipment applications include the following Tier 3-certified models: 1. PowerTech M 4.5L at 56 to 74 kW (75 to 99 hp); 2. PowerTech E 3.0L at 76 to 99 hp (57 to 74 kW); 3. PowerTech E 4.5L at 85 to 140 hp (63 to 104 kW); and 4. PowerTech E 6.8L at 140 hp (104 kW).

Interim Tier 4 Solutions for 2011

At CONEXPO-CON/AGG 2008, JDPS announced the technology solutions it will use to meet the stringent Interim Tier 4 mobile off-highway emissions regulations for engines 130 kW (174 hp) and above that start in 2011. John Deere will start with its proven Tier 3 PowerTech Plus engine platform, add an exhaust filter consisting of a diesel oxidation catalyst (DOC) and diesel particulate filter (DPF) unit for reducing particulates (PM) and increase the percentage of cooled exhaust gas recirculation (EGR) for NOx control.

Because regulations for engines less than 130 kW (174 hp) don’t start until 2012, JDPS has not introduced the technologies it will utilize for this power band. However, John Deere is evaluating EGR and exhaust filters, as well as other technologies, for meeting emissions for the lower horsepower categories. John Deere was successful in offering multiple technology solutions to match market needs for Tier 2 and for Tier 3, and JDPS will likely do something similar for Interim Tier 4.

Where Can You Find Them?

All of the above-mentioned engines fit in such compact equipment as compact track loaders, mini excavators, loader backhoes, crawler dozers, crawler loaders, wheel loaders, skid steers, air compressors, generator sets and more, depending on the size and brand of the machine.

Reaching New Tiers Explaining Emission Standards for Off-Highway Diesel Engines

With a keen eye on a cleaner future, the construction manufacturing industry is producing eco-friendly machines — especially cleaner burning diesel engines for the construction, landscape and agricultural industries. From compact skid steers to excavators, government-issued Tier emission standards are mandating that machine engines (from engine manufacturers like Cummins to Caterpillar) produce far less pollution — particulate matter (PM), oxides of nitrogen (NOx) and carbon monoxide (CO) and hydrocarbons (HC). These emission regulations — called Tier standards — were created by the Environmental Protection Agency (EPA) more than a decade ago for off-highway diesel engines; each sector has similar standards and deadlines. For the construction industry, off-highway diesel engine Tiers are coming to a head as the final and most stringent set of regulations (called Tier 4) are already here for small diesel engines. The 25- to 74-hp power band hit Interim Tier 4 in 2008 and the Final Tier 4 standards for all horsepower ranges are fast approaching in 2013 through 2015. The primary focus of the Tier standards is the reduction of the oxides of nitrogen and particulate matter. There are two deadlines for Tier 4 off-highway diesel engines — Interim and Final. The initial Interim standards deal with PM compliance, while the Final standards deal with NOx and HC compliance. For engines 25 to 74 hp, Interim Tier 4 has already started, and because the regulations vary by horsepower, different engines will require different technologies. Most diesel engines emission reductions for 74 hp and below are using advanced in-cylinder combustion systems without the need for exhaust after-treatment for that power band. It’s the bigger diesel power plants (75 to 751 hp) that will see the latest new emission gizmos, which includes after-treatment systems that will need to be added to the engine to further control NOx and PM pollutant levels.

Honda Engines

Nearly 40 Models of Gas Power Plants in Four Basic Compact Configurations

The Company

Honda is the world’s largest manufacturer of gas engines, producing and marketing approximately 22 million units globally for automotive, motorcycle, marine and power equipment products. Honda four-stroke engines are clean, fuel-efficient and optimal for multiple power applications. The company currently produces 37 models of general-purpose engines with more than 400 variations and the industry’s widest variety of four-stroke outboard engines. Honda manufactures engines and other components around the world and maintains assembly plants at locations that best serve its customer base. Honda’s Swepsonville, N.C., Power Equipment plant, for example, employs 550 people in the United States, and represents an investment of more than $140 million in domestic manufacturing capabilities.

Innovative Compact Engine Lineup

Nearly all Honda engines going into work applications are compact. Honda engines supply smooth, low emission, dependable power for more than 3,000 different product applications ranging from lawnmowers to go-karts.

Honda produces 37 models in four basic configurations. The Mini Four-Strokes include two models that can be found in hand-held portable equipment. The GX Series (overhead valve) includes 21 models, typically found in commercial and rental equipment. The GS (overhead cam) Series includes two models for premium residential and light-duty commercial markets. The GC (overhead cam) Series has nine models in total in both single cylinder versions and V-twin configurations. GC Series engines are designed specifically for premium, high volume residential power equipment applications.

In October of 2008, Honda Engines introduced a new series of general purpose engines specifically and solely designed for pressure washer applications. Honda’s GX200TQAPW, GX390T1QAPW and GCV190LAN5AP engines are uniquely designed to provide smooth and reliable power to a variety of residential and commercial pressure washers. All three engines have been expressly tuned to provide maximum pressure washer output and feature exclusive components designed to match the needs of pressure washer users. Maximum power for the engines is achieved via improved engine cooling, while special induction components enhance engine breathing.

One Engine for All

In January 2007, Honda Engines began certifying its models to the new, lower CARB 2007 and existing EPA Phase 2 emission requirements by offering 50 state compliant engines only. As a result, new Honda overall emission levels will be reduced by more than 32 percent. This means that in addition to meeting the new, more stringent California emission requirements, Honda Engine emission levels meet or exceed all EPA requirements. The development of one engine for use in all 50 states continues to reflect Honda’s forward thinking with regards to emission regulations, air quality and the needs of its customers. With advanced engine technology, Honda certifies to new CARB exhaust and evaporative emissions requirements without the use of a catalytic converter.

Where Can You Find Them?

Honda Engines supply reliable power for applications and machines such as hand-held portable equipment, pressure washers, commercial mowers, lawn tractors, tillers, pumps, snowblowers, generators and rescue and construction equipment.

Cummins Engines

Offering Three Series of Innovative and Compact Diesel Iron

The Company

Cummins Inc., a global power leader, is a corporation of complementary business units that design, manufacture, distribute and service engines and related technologies, including fuel systems, controls, air handling, filtration, emission solutions and electrical power generation systems. Headquartered in Columbus, Ind., Cummins serves customers in more than 160 countries through its network of 550 company-owned and independent distributor facilities and more than 5,000 dealer locations.

Innovative Compact Engine Lineup

Since Cummins introduction into the compact engine market, their business has grown rapidly. Cummins compact engine lineup includes their A Series engines, as well as their mechanical B3.3 and electronic QSB3.3 and QSB4.5.

The A1700, A2000 and A2300 engines offers a full range of three- and four-cylinder options ranging from 31 to 60 hp with up to135 lb-ft of peak torque. These engines have been known for their reliability since launch and continue to give customers improved productivity.

The Cummins B3.3 is designed for dependable, long-lasting performance and has ratings from 60 to 85 hp and 224 lb-ft of peak torque. The B3.3 also shares the same installation footprint as the 80- to 110-hp electronic QSB3.3, allowing the OEM to engineer one basic installation through a higher power band. This offers a product lineup from 60 to 110 hp with virtually no modifications to the equipment. The QSB3.3 delivers up to 110 hp in a much smaller and lighter package than any 4.0- to 4.5-liter engine.

Cummins’ QSB4.5 engine is also available for your 110 to 170 hp needs. Similar to the QSB3.3, the QSB4.5 combines proven full-authority electronic controls with the reliable performance you expect from one of the most successful and durable engine designers.

Innovative Tier 4 Solutions

Cummins was the first to reach Tier 4 emissions in early 2007, almost one year before the emissions change for engines below 49 hp, according to company officials. This was believed to be the first production engine certified to meet the Tier 4 requirements and is a major achievement considering Tier 4 Interim represents a 50 percent reduction of particulate matter vs. Tier 2.

Every one of Cummins’ engines under 75 hp is certified to Tier 4 standards using Cummins in-cylinder technology, which means no change to the engine through 2013. This also means you can rest assured that you won’t have to re-engineer your equipment to adapt to changing regulations for at least five years in the United States and up to ten years throughout the rest of the world. Cummins was also the first in the industry to announce Tier 4 solution for engines above 174 horsepower. Please see www.everytime.cummins.com for more information on its emission technologies.

Where Can You Find Them?

You can find Cummins powered equipment in all applications such as skid steers, forklifts, turf equipment, telehandlers, compact tractors, pumps, compressors, gen sets, road compaction and ground support equipment. Cummins is growing its focus on compact engine equipment needs and its engines can be found throughout the world at any one of its 550 distributor locations in 160 countries.

Yanmar Engines

A Pioneer in the Creation of Compact Diesel Power

Yanmar has been producing diesel engines since 1933 and has manufactured more than 15 million diesel engines ranging from 4.5 to 5,000 hp. Today more than 1 million Yanmar diesel engines are powering North America’s leading edge mobile and stationary off-highway products. From construction equipment, generator sets, pressure washers and turf equipment to military applications and agricultural machinery, Yanmar North America is a pioneer in compact diesel power. Yanmar developed the world’s first practical small diesel engine. Founded in 1912, Yanmar provides compact diesel engines to over 130 countries around the world.

Innovative Compact Engine Lineup

Yanmar’s newest engine line is the MINIMAX Series which was introduced at the 2007 GIE EXPO. This lightweight powerhouse debuted at 784 cc, and for the 2008 GIE EXPO, a slightly larger version was released with 903 cc of displacement. These high output, compact diesels generate 18.9 and 22.9 hp, respectively, and are designed for a variety of applications where lightweight, high power and low vibration are mandatory.

Yanmar introduced its new TNV Series of compact diesel engines in 2003. The lineup includes 10 TNV models stepped from 13.8 to 85.6 gross hp. The Yanmar model 3TNV82A exemplifies one of its most popular engines. It is rated at 24.7 hp at 2,500 rpm as utilized in the 6,306-lb (operating weight) Yanmar Vi027 mini excavator. The 3TNV82A three-cylinder, liquid-cooled diesel engine represents 21st century engineering and is designed to meet Tier 3 and 4 emission requirements employing only simple mechanical controls. No electronic controls are needed. Improvements to the combustion and FIE systems result in cleaner combustion through refined air intake design.

A newly developed inline fuel injection pump provides the same level of FIE performance as found in Yanmar’s direct-injection engine models. A load timer adjusts injection timing in accordance with engine load. A fuel-damping valve built into the delivery portion of the fuel pump stabilizes the pressure remaining after injection and prevents any secondary injection of fuel. Quieter operation also received close attention when making the TNV Series. A molybdenum coating in the piston skirt in combination with optimized clearance between the piston and cylinder reduces unwanted piston slap. Mechanical gear noise is minimized by the use of a smaller module for the valve timing and fuel injection pump in conjunction with improved tooth profiles.

Where Can You Find Them?

Yanmar compact engines power machines such as mini excavators, wheel loaders, skid steers, track loaders and more. TNV Series compact diesel engines power more than 175 OEMs alone. Popular compact construction equipment that utilizes Yanmar diesel engines include Volvo, Mustang, Komatsu, Case, Gehl, Doosan, John Deere and Takeuchi, as well as New Holland and Wacker Neuson.

Fluid Engine Upkeep

Protect the Heart of Your Next-Gen Engines by Maintaining Oils, Coolants and Fuel

By Jennifer Oredson

At the core of your compact equipment is a power plant — an engine that provides the essential energy for that machine to multifunction — whether it’s a generator or a skid steer loader. Protecting that nucleus is one of the most crucial requirements for any type of equipment maintenance. Considering engine oil type, diesel fuel and coolant quality has always been important, but also weighing the technologies needed to meet Interim and Final Tier 4 emissions regulations has become increasingly important to correctly ensure engine preservation. When considering both, keep these important preventative maintenance tips in mind for the next generation of diesel engines.

Essential Oils

“Keep in mind, not all products on the market are optimized with off-highway conditions in mind,” explains Dr. Ken Chao, a senior engineer at John Deere Power Systems (JDPS) in Waterloo, Iowa. “There’s a big difference between on- and off-highway oils. Off-highway applications are subjected to higher loads, higher crankcase oil temperatures and higher levels of sulfur, dust and moisture contaminants — all of which can lead to excessive wear on the engine.”

With the introduction of exhaust filters in many Interim Tier 4 engines, the type of engine oil used can have a significant impact on the proper functioning and service life of these devices. It is likely that many off-highway manufacturers will recommend using CJ-4 oil with Interim Tier 4 engines. It is important, however, to always follow the manufacturer’s oil-type and service-interval recommendations.

Companies that manufacture off-highway engine oils have been able to attain the lower sulfur, ash and phosphorus levels required under CJ-4 specifications by using new additives that provide improved thermal protection. And, compared to CI-4 oils, CJ-4 has been shown to be much more stable and to have better soot-handling capabilities.

“Heat affects off-highway engines much more than on-highway,” Chao says. “Off-highway engines work much harder in heavily-loaded conditions. Plus they don’t get the cooling effect from highway travel. Every time you raise the temperature 10 degrees Celsius [about 20 degrees Fahrenheit], you double the oxidation rate of the oil.”

Lab and field tests reveal that the superior anti-wear additives in quality engine oils can significantly reduce engine wear, increasing the productive life of the engine. They also extend drain intervals and reduce piston deposits, which leads to a cleaner engine that will last longer and provide consistent power. John Deere Plus-50 oil, for example, provides a 50 percent increase in the drain interval on John Deere engines over the engine operator manual recommendations.

Fuel for Thought

As more sophisticated emissions-control technologies are added to diesel engines — and with the increasingly stringent EPA emissions regulations — fuel quality is more important than ever.

Prior to October 2007, sulfur content levels of typical off-highway diesel fuel could be 1,000 to 3,000 parts per million (ppm). Sulfur content in off-highway fuel was reduced to 500 ppm (low sulfur diesel) in 2007 and will be further reduced to 15 ppm (ultra-low sulfur diesel or ULSD) in 2010. Probably 90 percent of off-highway diesel fuel is already at 15 ppm. ULSD will enable the use of exhaust filters on new engines and reduce emissions from the existing diesel engines.

The increased interest in and use of biofuels also demands strict adherence to applicable fuel quality standards. Most off-highway diesel engine manufacturers allow equipment operators to use biodiesel in varying concentrations, providing that users follow strict quality standards.

For example, JDPS prefers that operators use 5 percent blends (B5), but the company allows the use of biodiesel concentrations up to a 100 percent blend (B100) in all John Deere engines, including all non-emissions-certified engines. However, there are several caveats. The biodiesel (B100 portion) must meet ASTM D6751 or EN14214 specification. Any blend B20 or higher is required to use a John Deere-approved fuel conditioner containing a detergent/dispersant. John Deere also encourages biodiesel users to purchase biodiesel blends from a BQ-9000 Certified Marketer and to source from a BQ-9000 Accredited Producer, as certified by the National Biodiesel Board. Certified Marketers and Accredited Producers can be found at www.bq-9000.org.

Careful of the Coolant

Heavy-duty cooling systems require special care and year-round protection. Not all antifreeze/coolants on the market provide the necessary protection a cooling system needs to operate efficiently under extreme pressures and temperatures. So it’s important to be selective. John Deere Cool-Gard II, for example, is a fully formulated antifreeze/summer coolant, designed and extensively tested to protect wet-sleeve-liner diesel engines from cylinder-liner cavitation erosion. This is especially critical for heavy-duty, off-highway applications that often endure punishing conditions and temperature extremes.

When Calvin Conley of Diesel Energy Systems of Fredericksburg, Ohio, services an engine, he becomes a firsthand witness to the benefits that quality oil and coolant offer his customers.

“We routinely get 30,000 hours out of a well maintained engine,” Conley says about his service center. “The key to that longevity is servicing the engine at the right intervals and using an oil and coolant designed for the engine and application.

“We use oil-sampling kits to determine when to service the engine,” he says. “The result is fewer oil changes, less downtime required to service the engine, and less oil and filters to store and dispose of. We’re saving roughly 11 gal of oil per machine each year. When you total all of the engines that we service, that’s a significant savings for everyone involved.”

Jennifer Oredson is a technical writer for Two Rivers Marketing, based in Des Moines, Iowa.

SCR vs. EGR Two Technologies Battle for Tier Emission Supremacy

Each manufacturer is turning to a number of unique technologies to most efficiently reduce emissions and please customers, but there are still two prominent schools of thought — SCR and EGR. Selective catalytic reduction or SCR is a technology that uses a urea-based solution to reduce NOx. The urea solution is mixed with engine exhaust gases in the catalytic converter turning the NOx to oxygen, nitrogen and water. SCR is already used in European truck and car engines, and some U.S. manufacturers have announced that they will begin using the technology in on-highway engines beginning in 2010 (Detroit Diesel and Freightliner, for example). But most North American companies seem to be turning to cooled exhaust gas recirculation (EGR) strategies, which lowers an engine’s peak combustion temperature to lower NOx output. Both sides have made compelling arguments. The EGR camp says that SCR requires additional components and is overly complex; urea may not be widely available in the Tier timeframe and SCR is unproven in North America. While not many companies have announced they will use SCR technology in North America as of yet, Tognum subsidiary MTU Detroit Diesel unveiled its Tier 4 Interim compliant Series 900 engines outfitted with SCR technology at CONEXPO-CON/AGG. Companies like MTU Detroit Diesel counter that it is a proven technology not only in European vehicles, but also in a wide number of other applications, including coal-burning energy plants in the United States. They argue that urea availability issues are not so difficult and that SCR is the only way to meet emissions standards without sacrificing fuel economy. In fact, proponents of SCR insist they will deliver a significant fuel economy improvement over today’s engines. Yet, big North American companies like John Deere and Cummins have noted they will be using EGR in their engine systems — at least for Interim Tier 4.