1104D Mechanical
Transient Performance Characteristics
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Introduction
The 1104D Mechanical represents a significant achievement in providing our customers
with a minimum-impact route to Tier 3 compliance and provides a market-leading level of
power density & performance. However, Tier 3 emissions limits in this power range are
significantly tighter than at Tier 2 and this effectively limits the range of possible
‘adjustment’ to optimise engine performance. Customers are likely to identify some
changes in the response characteristics of the engine, when compared to a comparable Tier
2 model. In many cases, these changes will be insignificant, or may be overcome by finetuning of the installation/ driveline; in other cases, the customer requirements may be
more effectively satisfied through the selection of a different engine configuration.This
presentation is the front piece to a package of information that sets out to:
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Reinforce the positioning of the 1104D Mechanical product within the range;
Define areas where customers might see a change in machine operating characteristics;
Identify areas where compensating adjustments could be made to machines;
Provide guidance as to the sensitivity of various application types to these issues;
Suggest the most suitable engine configuration for specific customer sensitivities
The objective is to ensure that the customer has enough information to make an informed
selection of the most appropriate engine configuration for the application.
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Presentation Overview
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Section 1:
 1104D Product Positioning
Customer Expectations at Stage IIIA/ Tier 3
Section 2:
 What is Transient Response?
 1104D Transient Characteristics
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Section 3:
 IPSD Journey to Stage IIIA/ Tier 3 Mechanical
Section 4:
 Selling the transient message
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Section 1
Product Positioning at Stage IIIA/ Tier 3
‘Selling the Range’
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Section Agenda
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Tier 3 Product Positioning Overview
 Electronic Positioning
 Mechanical Positioning
Customer Expectations at Stage IIIA/ Tier 3
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Tier 3 Product Positioning Overview
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Transient concerns (smoke & response) can be avoided by selecting
the right product for the application
Strong 4.4L product range at Stage IIIA/ Tier 3
 Electronic & Mechanical offering
 Power range overlap
 Unique sales propositions
Mechanical offering = Minimal change
Electronic offering = Optimum Stage IIIA/ Tier 3 performance
Mechanical product offers significant commercial benefits but won’t
provide the performance benefits of the Electronic product
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Electronic Positioning
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Utilises proven components of Caterpillar ACERT™ technology
 Common rail fuel system
 Smart wastegate turbocharger
Performance optimised across the
load and speed range
 Optimised SFC
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Minimised heat rejection
Electronic Control means Optimum Tier 3 Performance
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Mechanical Positioning
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Design goal to maintain as close to Stage II/ Tier 2 performance with
minimal external changes
Development focus on internal improvements:
 Combustion chamber
 Air system (camshaft & cylinder head)
 Fuel Injection
 Cooling system
Mechanical Control means Minimum Change from Tier 2
Ease of Changeover
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Mechanical Positioning
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Package virtually identical to Tier 2 & Tier 0
 Identical major hook-up points
 Minimal visible external changes
 Common front and rear ends
Many components carried over (95%)
 Product reliability
 Minimised additional parts inventory
 Streamlined training
 Consistent serviceability
Low OEM investment costs
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Minimised engineering costs
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Customer Expectations at Tier 3
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‘The next generation is always better’
‘The engine will be more responsive at Tier 3’
‘The engine will have less visible smoke at Tier 3’
General Customer Expectations:
 Driveability = Tier 2 or better
 Smoke = Less visible smoke
 Power/ Torque = Tier 2 or better
 Fuel Consumption = Minimal change
 Package Size = Drop-in solution
 General Performance = Improvements
In reality, achieving a Mechanical offering at Stage IIIA/ Tier 3 results
in some compromises (especially levels of visible smoke and low speed
response)
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Section 2
1104D Mechanical
Transient Response Characteristics
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Section Agenda
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Transient Performance Overview
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What is Transient Response?
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1104D Mechanical Transient Response Characteristics
 Load Acceptance from Low Idle
 Loaded Acceleration from Low Idle
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Acceleration from a Loaded Condition
Free Acceleration Smoke (FAS)
Loaded Acceleration Smoke
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Transient Performance Overview
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Emissions
 Challenge was significant for Mechanical products at Stage IIIA/
Tier 3
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Challenge is shared by the competition
Transient characteristics are different at Stage IIIA/ Tier 3 due to
the technologies employed to achieve emissions legislation
Customer Management
 Understand the transient characteristics of the 1104D
 Manage customer expectations accordingly
 Match the right product to the right application
 Utilise the full product range, it is a key strength!
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What is Transient Response?
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Responsiveness of the Machine
 Load acceptance from low idle
 How the engine responds when applying sudden load
 Loaded acceleration from low idle
 How the machine performs accelerating from a standing start
 Acceleration from a loaded condition
 How the machine feels accelerating through the speed range
Smoke
 Free Acceleration Smoke (FAS)
 Level of black smoke when blipping the throttle from idle with
the machine in neutral and any PTO unloaded
 Loaded Acceleration Smoke
 Level of black smoke generated during acceleration with the
machine loaded
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1) Load Acceptance from Low Idle
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How the engine responds when applying sudden load?
Load Acceptance from Low Idle degradation from equivalent Stage II/
Tier 2 model
 1104D-44: -10%
 1104D-44T: -20%
 1104D-44TA: -10%
The trade-off between low speed, un-boosted torque and Free
Acceleration Smoke (FAS) has been optimised for all ratings by the
Engineering team at IPSD
Customers can increase low idle speed, or rematch machine
transmission and hydraulic demands, to further improve performance
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2) Loaded Acceleration from Low Idle
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How the machine feels to the operator when accelerating from
a standing start with a heavy load?
Loaded Acceptance from Low Idle degradation from Tier 2
 1104D-44NA: -10%
 1104D-44T: Dependent on machine loading characteristics
 1104D-44TA: Dependent on machine loading characteristics
Atmospheric Boost Control (ABC) will improve performance
 IPSD offers two variants of low pressure options to best match to
application
Customers can increase low idle speed, or rematch machine
transmission and hydraulic demands, to further improve performance
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3) Acceleration from a Loaded Condition
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How the machine feels to the operator when accelerating
through the speed range?
1104D will achieve boosted fuel at lower manifold pressure than the
1104C Stage II/ Tier 2 range
The product will feel more responsive in many circumstances
Naturally Aspirated product (1104D-44) will see a degradation of
around 10% compared to Stage II/ Tier 2
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4) Free Acceleration Smoke (FAS)
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Level of black smoke when blipping the throttle from idle with
the machine in neutral and any PTO’s unloaded?
FAS will be higher than 1104C but within legislation requirements
(including Switzerland & Austria)
 There will be visible black smoke at Stage IIIA/ Tier 3 Mechanical
Smoke acceptability is highly subjective
Manage customer expectations relative to Stage II/ Tier 2 product
Certain markets will be more sensitive to smoke than others
The trade-off between low speed, un-boosted torque and Free
Acceleration Smoke (FAS) has been optimised for all ratings by the
Engineering team at IPSD
Customer improvements can be made by optimising drive train
inertias and managing engine acceleration
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5) Loaded Acceleration Smoke
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Level of black smoke generated during acceleration with the
machine loaded?
Loaded Acceleration Smoke will be higher than 1104C
Smoke levels are highly subjective and will need to be assessed at the
customer level
Flag the issue to Applications if…
 The customer is in a highly smoke sensitive market (e.g.
Scandinavia)
 The environment the machine is operating in requires no visible
smoke (e.g. indoor)
 The machine will be performing a lot of complex operations (e.g.
Shovel Loader)
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Section 3
IPSD Journey to Tier 3 Mechanical
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Section Agenda
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Emissions
Technology Choices
IPSD Tier 3 Solution
Performance Comparison: Tier 2 to Tier 3
1104D Mechanical Performance
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Tier 3 Emissions Challenge
Experience from on-highway
development shows that Tier 3
levels of NOx would typically
require Electronic FIE strategies.
Some engine manufacturers have
achieved Tier 3 levels with rotary
mechanical FIE, using innovative
technological approaches.
Heavy-Duty Diesel NOx-PM Trade-Off By
Technologies and Legislation
Tier 3 Off-Highway
<75kW
IPSD will offer a full range of
mechanical products between 54.5
and 83kW, from NA to TA to meet
the needs of each customer.
Needham, J., 1991. "Engine Experience and EPA Regulations", University of
Minnesota Short Course “Diesel Particulate Matter”, October 1991
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Technology Options at Tier 3 Mechanical
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Air System
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Charge-Air Cooling
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Variable Geometry Turbo (VGT)
Fuel System
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Multi-Shot Injection
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Injection Rate Shape
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Injection Retard
Combustion System
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Re-Entrant Piston Bowl
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Quiescent Combustion (with highpressure FIE)
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Optimised port swirl
General
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Reduce Engine Parasitics
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Optimise Torque Curve Shape
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IPSD Stage IIIA/ Tier 3 Solution
IPSD has achieved Tier 3 emissions standards with minimal customer
impact and maximum carry over of today’s proven design by innovative
development of:
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SFC, heat rejection,
and transient response
trade-off optimised
Air system strategies
FIE
Combustion chamber
FIE boost control
Engine
Rating
Aspiration
FIE
Combustion
General
1104D-44TA
1104D-44T
1104D-44
68 – 83kW
55 – 75kW
54 – 56kW
Turbo After-Cooled
Straight Turbo
Naturally
Mechanical Rotary FIP
Rising Rate Injection
Dynamic AFR Control *
Mechanical Rotary FIP
Rising Rate Injection
Dynamic AFR Control *
Mechanical Rotary FIP
Rising Rate Injection
Re-Entrant Piston
Re-Entrant Piston
Re-Entrant Piston
Hi-Efficiency Water
Pump
Hi-Efficiency Water
Pump
Hi-Efficiency Water
Pump
* Patents applied for
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Performance Comparison: Tier 2 to Tier 3
400
Tier 2
Tier 3
380
Torque [Nm]
360
Full-load torque curves
are similar for Tier 2 and
Tier 3 ratings
340
However, un-boosted
torque is lower on Tier 3
due to emissions control
strategies
320
300
280
260
240
220
200
800
1000
1200
1400
1600
1800
Engine Speed [rpm]
Tier 3 Concerns:
• Low-speed load acceptance
• Acceleration from low idle
• Operating close to smoke limit
2000
2200
The penalties of low unboosted torque have been
offset to some extent by
management of fuelling
control to transition to
fully-boosted torque at
lower speed
Tier 3 Strengths:
• Competitive mechanical strategy
• More responsive from part load than Tier 2
• More lugging capability than Tier 2
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1104D Mechanical Performance
1104D
Mechanical
versus 1104C
Tier 3 Market Standard
versus Tier 2 Market
Standard
BSFC
+5%
+ 5 to +10 %
Heat Rejection
+5%
+ 5 to +10 %
Noise
-1 dBA
-
Altitude
3000 m
3000m
Oil Change
250 to 500 hrs
250 to 500 hrs
Load Acceptance
(from low idle)
TA
–10%
Turbo
–20%
-10 to -25%
Performance Features:
 BSFC and heat rejection believed to be highly competitive
 Noise reduction over Stage II/ Tier 2 will be noticeable
 Load acceptance and response believed to be competitive
 Reliability and durability as Stage II/ Tier 2
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Section 4
Selling Transient Messaging
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Section Agenda
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Competitive Landscape
Transient Sales Messaging
Transient Response – Practical Approach
What should I be doing?
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Competitive Landscape
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Competition will have a similar, or greater, challenge with Transient
Performance at Stage IIIA/ Tier 3
Technology choices are the same for all competitors marketing
Mechanical product
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Cummins QSB 3.3
 Reduced displacement 4 Cylinder engine
 Expect Load Acceptance from Low Idle degradation from Stage
II/ Tier 2 of around 25%
Competition using for example AVL TINER system
 Expect Load Acceptance from Low Idle degradation from Tier 2 of
around 10% to 25%
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Transient Sales Messaging
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Product Benefits
 Competitive Mechanical
Product Strategy
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Strong Sales Proposition
Strong Steady State
Performance
Responsiveness from Part
Load same or better than
Stage II/ Tier 2
Lugging Capability same or
better than Stage II/ Tier 2
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Product Sensitivities
 Low Speed Load Acceptance
 Acceleration from Low Idle
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Transient Smoke
Product sensitivities are
application dependent.
Selection of the right product,
and managing customer
expectations, is the key to
avoiding transient issues
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Assessment of Transient Acceptability
Transient acceptability is largely subjective. The following criteria
should be considered in relation to a specific customer requirement:
• Level of transient operation
• Customer brand proposition
• Sensitivity to visible smoke
Score
Level of Transient
Operation
Customer Brand
Proposition
Environmental
Sensitivity to Smoke
Typical Machine
1
Constant Speed
Value Machine
Outside / Ag
Pump set
2
Lugging / Roading
3
Shuttling / Pull-Away
4
Digging
5
Loading
Ag Tractor
Mid-Range Machine
Construction Site
FLT
Telehandler / BHL
Premium Machine
Indoor / Warehouse
Wheeled Loader
This information is graphically represented on the next slide.
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Engine Selection: Practical Approach
5
1104D
Electronic
4
3
2
1
1104D
Mechanical
1
2
3
4
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5
What should I be doing?
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Determine if any of your customers are sensitive to smoke or
response based on territory and application
Make customers aware that the transient characteristics of the
1104D are different from Stage II/ Tier 2
Manage customer expectations accordingly
 Smoke, although highly subjective, is worse than Stage II/ Tier 2
 Machine responsiveness will be different at Stage IIIA/ Tier 3
Sell the strong product benefits, there is a positive side to the
transient story
 Steady state performance has improved over Stage II/ Tier 2
 Product is more responsive from part load
 Product has additional lugging capability
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Strong position vs. other mechanical offerings in the marketplace
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Summary
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1104D Mechanical is a highly competitive product with a strong sales
proposition
Transient concerns can be avoided by matching the engine to the
application/ transmission and by managing customer expectations
relative to Stage II/ Tier 2
Transient response characteristics of the 1104D are part of the Stage
IIIA/ Tier 3 Mechanical story for all suppliers in the industry selling
Mechanical product
Applications Teams have been briefed on 1104D Transient
characteristics. Please contact your Applications Engineer if you have
any questions or concerns
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