Clean Power for Today

Transcription

1 Clean Power for Today How Emissions Standards Affect Our Products and Customers

2 Table of Contents Section Page Regulations for Diesel Engines...1 Technologies...2 Kubota Solutions by Horsepower Class...3 Explanation of Each Technology i. DPF Diesel Particulate Filter ii. EGR cooled Exhaust Gas Recirculation iii. CRS Common Rail fuel injection System iv. SCR Selective Catalytic Reduction Emissions Control Component Location...9 The Operator Experience...10 How is Regeneration Controlled? i. What does the Operator Need to Do? ii. Lamps & Switches Emissions Information Summary...13 The Kubota Dealer s Role...14 Warranty & Dealer Support...15 About Kubota

3 Regulations for Diesel Engines The Environmental Protection Agency (EPA) has introduced standards to reduce air pollution from Diesel engines in stages or Tiers. The Tiers depend on engine horsepower (HP) and year of manufacture. The goal is to reduce black exhaust smoke (Particulate Matter or PM), Hydrocarbons (HC), Nitrous Oxides (NOx, a major component of smog), and Carbon Monoxide (CO). The following chart shows Tier implementation by year and horsepower group. Horsepower Group Year <25.5 HP 25.5~50 HP 50~75 HP 75~101 HP 101 ~ 175 HP 2011 Tier Interim Tier Final Tier 4 Beginning with engines manufactured in 2013, all Kubota diesel engines that are rated at less than 75 Horsepower (HP) must meet Final Tier 4 regulations. Engines rated at 75 HP and above must meet interim Tier 4 (it4) regulations. * By 2015, all diesel engines manufactured by Kubota must meet Final Tier 4 regulations. * *Certain exclusions apply 1

4 Technologies The need to reduce black smoke (PM) and limit NOx at the same time was a challenge for Kubota engineers. Diesel fuel burns more efficiently when combustion temperatures are high, leading to less unburned fuel (soot) emitted through the exhaust pipe. On the other hand, high combustion temperatures also increase the production of NOx, a key component of photochemical smog. Kubota s solution to conquer both problems includes the following technologies: DPF Diesel Particulate Filter EGR Exhaust Gas Recirculation CRS Common Rail fuel injection System An additional technology that Kubota is not presently using is called Selective Catalytic Reduction (SCR). An explanation of each technology appears on pages

5 Kubota Solutions by Horsepower Class Kubota is implementing different solutions depending on engine horsepower, applications, and emission Tiers. Small engines under 25 HP can comply with Tier 4 through Kubota s design and efficient control of the combustion process and without need for DPF mufflers. Larger engines require one or more of the technologies explained on the subsequent pages. This table shows which technologies apply by Horsepower Class. Engine Horsepower Class Technology To Meet <25.5 HP Kubota engine design Tier to 35 HP 36 to 75 HP 76 to 135 HP Kubota engine design + EGR + DPF Kubota engine design + EGR + CRS + DPF Kubota engine design + EGR + CRS + DPF Tier 4 Tier 4 Interim Tier 4 Note: Certain Kubota models are not presently utilizing these technologies, as the EPA has allowed manufacturers to use existing engine designs for a limited time. 3

6 Diesel Particulate Filter (DPF) The DPF removes black soot (Particulate Matter) from the exhaust gas, so that there is no longer any visible smoke from the exhaust pipe. There are two major parts - the Diesel Oxidizing Catalyst (DOC) and the Diesel Particulate Filter (DPF). Exhaust Gases 4

7 The DOC has two jobs. First, any Hydrocarbons (HC) or Carbon Monoxide (CO) are converted into water and CO2. Secondly, the DOC provides the heat necessary to activate the Regeneration Cycle. The DPF element catches particulate matter (soot) before the exhaust reaches the atmosphere. After approximately 15 to 20 hours of operation, the accumulated soot must be burned away (the time depends on operating conditions). Regeneration is the process of burning the accumulated soot from the DPF. Kubota customers can choose automatic regeneration or can choose to delay regeneration until the equipment is located in a non combustible area outdoors. It depends on the engine load, but regeneration typically takes about 20 minutes. Equipment operation can usually continue during regeneration. After regeneration is complete, there will be a small amount of unburned material, called ash, remaining in the DPF. Ash consists of Iron, Copper, Calcium, Zinc, and other trace materials that will not burn. The primary source of ash is engine wear, but fuel and lubricants also contribute. After hundreds of regeneration cycles and about 3000 hours of engine operation, the accumulation of Ash will reach a point that will require an off machine cleaning of the DPF. 5

8 Exhaust Gas Recirculation (EGR) Nitrous Oxides (NOx) are a significant cause of smog; the brown layer of air that hangs over many of our cities. EGR reduces NOx by cooling off the combustion process with the introduction of small amounts of cooled exhaust gas into the intake manifold. This system was first used by Kubota in the United States with the introduction of the M108S common rail engine in

9 Common Rail System (CRS) The Common Rail System (CRS) electronically controls the fuel injection quantity and timing, enabling high pressure injections in stages rather than all at once. Combustion rate is thus optimized for more power, increased fuel economy, greater efficiency, and lower engine noise. Electronic Fuel Injectors CRS Pump High Pressure Fuel Rail Engine Control Unit (ECU) 7

10 Selective Catalytic Reduction (SCR) SCR is a technology that injects a urea/water solution through a catalyst into the exhaust stream of a diesel engine. The urea sets off a chemical reaction that converts NOx into nitrogen and water, which is then expelled through the exhaust pipe. Source: dieselforum.org SCR is best suited for higher horsepower, heavily loaded engines, where the constant load minimizes the production of particulate matter. Kubota equipment is more commonly used intermittently, in applications with varying load levels. For those types of usage patterns, the DPF/EGR/CRS solution is more appropriate. Future emissions standards may require a combination of SCR and DPF/EGR/CRS for some applications. 8

11 Component Location (typical) DPF EGR Valve EGR Cooler CRS Pump Fuel Rail Fuel Filter 9

12 The Operator Experience Clean Power When an operator starts the engine of a Kubota machine equipped with a DPF, a pleasant surprise is the complete absence of visible exhaust smoke, even when the engine is at full power. The days of black smoke clouds billowing from a diesel engine are history. The lack of smoke does not mean a reduction of power. Rather, the Kubota design EGR, CRS, and DPF, provides increased power, fuel efficiency, and lower noise compared to a mechanically injected engine, while at the same time exceeding government standards for reduction of PM, NOx, HC, and CO. How is Regeneration Controlled? Kubota allows the operator to choose when and where to regenerate the DPF. If the machine is operated outdoors and in a non-combustible environment, automatic regeneration is recommended. If an Auto button is provided, it should be pushed when the engine is started to allow for automatic regeneration. Equipment without an Auto button defaults to automatic regeneration, which then can be stopped by pressing the inhibit switch. 10

13 What does the Operator Need to Do? If the machine is operated outdoors, and in a noncombustible environment, Auto Regeneration is recommended. Here s how to do it. Tractors so equipped: Press Auto Button Press immediately after starting the engine. Make sure it is lit at all times, unless you want to stop Regeneration. Equipment without Auto button: Check Inhibit Switch Default is Auto operation (lamp OFF). Push if you want to stop Regeneration. Otherwise, leave switch alone. All Equipment: Raise Engine RPM Lamp or Display Maintain high enough engine RPM to keep this lamp or display OFF. 11

14 Tractor Layout of Lamps & Switches (typical, location varies by model) Raise Engine RPM Lamp Auto Button (if so equipped) Compact Track Loader Inhibit Switch Raise Engine RPM Lamp Excavator Raise engine speed Now HP limited Inhibit Switch Raise Engine RPM Message 12

15 Emissions Information Summary The EPA has mandated that diesel engines become cleaner, and has introduced standards for all engine manufacturers. Kubota is fully compliant, and has chosen appropriate technologies to meet the standards. For most engines, a DPF (Diesel Particulate Filter) is used to reduce soot emissions (also called Particulate Matter or PM). The DPF replaces the standard muffler, and is located in about the same place. The accumulated soot must be removed (burned) approximately every 15 to 20 hours, in a process called Regeneration. The actual time depends on operating conditions. Kubota recommends Automatic Regeneration, if the equipment is used outdoors and in a non combustible environment. The engine RPM must be raised to enable regeneration (until the raise RPM lamp goes off). Regeneration takes about 20 minutes. If the operator does not enable regeneration in due time, a dealer service call may be necessary. When regeneration is underway, a small amount of white smoke may be observed emitting from the exhaust pipe. During regeneration, the exhaust temperature will rise. Therefore, regeneration should only take place when the machine is in a non combustible area and outdoors. 13

16 R The Kubota Dealer s Role Kubota has produced a series of operational brochures in both English and Spanish (tractors only). These are available from the Kubota Fulfillment Center. It is the Kubota dealer s obligation to provide this brochure during product delivery and explain the emissions control system and its operation. Every Operator s Manual also has detailed information, and each tractor or construction machine has a decal to alert operators. Estaciónese afuera activado activado Toma Toma de de fuerza fuerza (PTO) (PTO) en marcha mínima Inversor en neutral Presione el botón, luego, las RPM aumentan automáticamente hasta completar la REGEN. only in rs. the ens, unless dicator oes off. n flashing bustible Bip 0 minutes. just icator Operational Reminders: Important! This tractor is equipped with a Diesel Particulate Filter (DPF) If tractor is being used outdoors, and in a non-combustible area, push the AUTO button (will light up) If AUTO operation was not activated, and indicators flash, follow chart below If you see/hear Do this Result Beep Push button (lights up) Raise RPM until off 1 OR AND Activate or allow DPF Regeneration only in non-combustible areas and outdoors. Indicator Lamps and Switch What do they do? DPF REGEN Indicator Lamp (on panel) Lights up whenever REGEN is needed or in process (unless auto DPF REGEN is disabled). Para un aire más limpio Tier 4 y Tier 4 interim Soluciones para el control de emisiones (tractores L60, M60, M100GX - M135GX) Raise Engine RPM Indicator Lamp (on panel) Raise RPM until it goes off. REGEN inhibit switch (left side of seat) Lamp OFF Auto DPF REGEN is enabled. Lamp ON Auto DPF REGEN disabled. Lamp FLASHING DPF REGEN is necessary turn switch OFF. Stays ON until REGEN is complete. Park outside Parking brake ON PTO OFF Throttle at idle Shuttle in neutral Push button, then RPM automatically increases until REGEN is complete. Beep 2 AND La tecnología Kubota protege el medioambiente Kubota Tractor Corporation TRDPF2013 Important! This Construction Machine is equipped with a Diesel Particulate Filter (DPF) Allow or activate DPF Regeneration (REGEN) only in non-combustible areas and outdoors. A beep will sound when REGEN is in process or needed; an E code may also display in hourmeter panel. Es automático... 1 ON ON 2 ON AND 2013 Kubota Tractor Corporation CEDPF2013 Tan solo presione el botón (lea el reverso para más detalles) The Way to Cleaner Air Tier 4 and Interim Tier 4 Emissions Control Solutions 3/27/13 12:48 PM Operate normally FLASHING Raise RPM until OFF Operate normally ON until REGEN is complete. (L60, M60, M100GX M135GX tractors) If you see Do this EITHER OR BOTH Result 3 lamp flashing (located left side of Inhibit switch FLASHING AND operator station) Turn switch OFF (lamp will go Raise RPM until OFF Operate normally Kubota s Technology protects the environment. It s automatic... OFF) Just push the button (see back panel for details) It s under your control 3/26/13 10:13 AM The Way to Cleaner Air Tier 4 and Interim Tier 4 Emissions Control Solutions ( SVL75 2, SVL90 2, KX040 4, KX057 4, KX080 4, U55 4) Kubota s Technology protects the environment. Automatic just start the engine. Operator selected when conditions require. (see inside for details) 2 Y ubota flyer_svl90-2_r4.indd 1 3/26/13 1:25 PM 1 O Tractor Corporation SpTRDPF

17 Warranty Kubota provides all customers a 5 year/3000 hour (whichever occurs first) warranty on certain emissions control system components, such as the CRS, EGR, and DPF. It is important to note that DPFs which cannot be regenerated due to operator misunderstanding, are not warrantable. Therefore, it is critical that both the dealer and Kubota customer review and understand the DPF operating procedures before delivery of the equipment to the final customer. Dealer Support Kubota maintains fully staffed training and service departments to support our dealers. Our mission is to provide maximum reliability for our customers, by training our dealers in the proper diagnosis and repair of emissions control and other systems. This effort includes: Annual classes at Kubota Training Centers. Online courses from Kubota University. Expert advice through the Kubota Tech Center. Publications to help customers understand the new systems and their operation. 15

18 Quality Innovation Value... Kubota Corporation was established in 1890, and has been forward-thinking ever since. With companies and affiliates in more than 130 countries, Kubota Corporation based in Osaka, Japan, has become an international brand leader in a variety of products; full-size, sub-compact and compact tractors, gasoline and diesel engines, construction machinery, pipes, valves, pumps, and air-conditioning equipment. Kubota introduced the L200, the first compact tractor with big tractor features, to the United States market in Based on the enthusiastic response to this innovative product, Kubota s commitment to the United States market has been on a steep growth curve since that time, with Kubota USA affiliates now including research, manufacturing, distribution, credit and insurance operations - all developed to better serve Kubota dealers and customers. 16

19 with a Strong Tradition of Innovation Kubota Tractor Corporation, with headquarters in California, has four division offices providing sales, marketing, distribution, finance, service and parts support for Kubota dealers in their respective areas. Today, you can find Kubota products hard at work mowing, gardening, landscaping, farming, hauling, towing and transporting across America. The Kubota Promise Produce state-of-the art, quality products Lead the industry in engineering and technological firsts Respect the environment and protect our customers safety Provide uncompromising service Listen and respond to customer needs Value each customer relationship with integrity and respect Support professional dealers Manage with vision and leadership 17

20 Every Operator Must Remember Kubota recommends Auto Regeneration, if the machine is operated outdoors and in a non combustible environment. For Tractors with Auto Button, remember STAR ST art engine Press Auto button-will light up (when operating outdoors and in non-combustible environment) Raise RPM until lamp goes OFF For Machines without Auto Button ST art engine Raise RPM until lamp goes OFF Note: Inhibit switch should be OFF, when operating outdoors and in non-combustible environment. Use only Ultra Low Sulfur Diesel Fuel. If Bio Diesel is used, maximum content is 5%. Use only Kubota engine oil, or engine oils that meet API CJ-4 specifications Kubota Tractor Corporation EMM2013