Engine Manufacturers’ Engine Compliance Roundtable June 28th, 2006

1
FAPT
Engine Manufacturers Engine Compliance
Roundtable June 28th, 2006
2
Al Ambrosini Manager, Engine Marketing
International Truck and Engine Corporation
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Emissions Technology

• Hardware Strategies
• VG Turbo
• CAC
• EGR
• DOC
• DPF

4
International Exhaust Configurations
Temperature Sensor T3
DPF
Temperature Sensor T1
DOC
Pressure Differential Sensor
3 Bolt Flange
Temperature Sensor T2
5
Active Re-Generation

• In cylinder dosing
• Existing fuel injector adds a dose of fuel into
  the cylinder after the primary combustion has
  taken place
• Unburned fuel is exhausted out of the cylinder
  down to the DOC where it burns and generates
  additional heat for the DPF
• This additional heat in the DPF helps to convert
  the soot into ash. Ash has lower volume and back
  pressure than soot

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Emissions TechnologyEngine Oil Specifications
(CJ-4)

• Technical Requirements Limits on SAPS
• Sulfated Ash
• Phosphorus
• Sulfur
• Required to prevent catalyst poisoning and extend
  DPF service interval
• Total Base Number (TBN) will be 8 to 9, whereas
  CI-4 Plus has a TBN of 10-12. This should be
  offset with the ULSD
• Estimated availability for CJ-4 is October, 2006
• Will be backward compatible with pre-2007 engines

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Service Strategy for 2007

• No change in oil drain or other service intervals
• New engines will require CJ-4 oil
• CJ-4 will be backward compatible for older
  equipment
• Older CI-4 oil
• Likely will still be widely available
• May be significantly cheaper(Present estimates
  show CJ-4 to cost anywhere from 15 to 30 more
  than CI-4)

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Always Performing
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DT 466
MaxxForce DT
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(No Transcript)
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International Engine Family

• Naming will go into effect with 2007 engines
• Engines will be black/aluminum in appearance
• Badge will retain Blue image

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What stayed the same into 2004?
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What was new in 2004?

• Crankcase
• Cylinder Head
• Crank Shaft
• Valve Train
• Fuel System
• Turbochargers
• EGR System
• If you can point to it, it was new.

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So Here We Go Again in 2007?
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What stays the same this time?

• Crankcase
• Cylinder Head
• Crankshaft
• Valve Train
• Fuel System
• Turbocharger
• If you can point to it, it hasnt changed (or
  hasnt changed much)

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Whats new?

• Reliability Improvements
• Minor improvements to existing parts for improved
  reliability and durability
• Where possible, these are being launched prior to
  2007

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Whats New?

• Active Regeneration Strategy
• Level One Adjust parameters to raise exhaust
  temperature
• Level Two In Cylinder Dosing
• Late fuel injection
• Fuel exits with exhaust and combusts in DOC
• No Additional Hardware or Fuel Lines Required

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Whats new

• Engine Controller
• Added capability for control of after-treatment
• 32 bit processor
• Expanded Features

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Whats new

• Intake Throttle
• Helps control active regeneration process
• Helps raise exhaust temperature for Active
  Regeneration
• Protects DPF from high temperature damage

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Whats new

• Increased EGR system capacity
• Builds upon successful 2004 EGR system
• Adds a second EGR cooler on Intake side of engine
  for NOx emissions reduction

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Whats new

• Closed breather
• Centrifugal Separator
• Driven by Oil Pressure
• Very high efficiency
• No Service Required
• Mounted to crank case
• Similar to breather Mack and DDC will offer

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Molded Foam Wiring Harness

• Highest Quality
• Robust to chaffing and damage
• Easy to assemble and service
• Wiring has been a top reliability issue

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Belt Drive

• 10 Groove belt replaces 8 groove
• Improves belt life and allows additional
  accessory loads

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New Features for 2007

• Dual Air Conditioning Compressors from factory
• Engine mounted
• Uses Sanden
• Enhanced SD7
• Compressors
• (higher volumetric
• efficiency)

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New Features for 2007

• Top Loading Fuel Strainer
• Less Mess
• Easy Access

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MaxxForce DT Product Positioning

• Characteristics
• Configuration I6
• Displacement 7.6L (466 cu in)
• Power Output 210 - 300hp _at_ 2400 2600 rpm
• Peak Torque 520 860 ft lbs. _at_ 1450 rpm
• Aspiration Turbocharged
• Combustion System Direct Injection
• B10 / B50 Life 300,000 / 450,000 miles
• Dry Engine Weight 1480 lbs.

RE
73/7400
CE
FE
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MaxxForce DT

• The same great engines from International

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Aftertreatment Control SystemUser Interface

• Passive Regeneration No driver Notification
• Active Regeneration No driver Notification
• Forced or Manual Regeneration Driver must be
  notified
• This mode is not available to the driver during
  the normal driving cycle and requires additional
  vehicle level logic to work with the engine and
  aftertreatment controls to start the
  regeneration. This mode is performed in a
  standstill operation.
• But what if I cannot perform this process now?
  The vehicle will allow a certain amount of time
  before this process MUST be started. Additional
  warning levels and feedback will be provided to
  the driver to ensure that the filter and engine
  do not become damaged including de-rate of the
  engine to protect these sensitive systems

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Aftertreatment Control SystemUser Interface

• Stationary or Forced Regeneration
• Interlocks
• To ensure that the driver is in a safe
  environment and that the driver acknowledges that
  control of the vehicle will not be available to
  him until the STATIONARY regeneration is
  complete, International has devised a series of
  vehicle level controls to ensure that this
  procedure is both started and completed
  accurately
• Interlocks include
• Vehicle Speed 0
• Engine Speed Control NOT engaged
• Park Brake SET
• Automatic Transmission in NEUTRAL or PARK
• Brake Pedal NOT depressed
• Clutch Pedal NOT depressed
• Throttle Pedal NOT depressed
• STATIONARY REGENERATION REQUEST BUTTON PRESSED
• If any of these conditions are NOT met, the
  Request Button will flash, indicating the driver
  has started the process incorrectly, and the
  process will NOT start

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Maximum Exhaust TempsCurrent vs. 2007 Diesel
Engines
DOC

• PM reduction (plus HC CO)
• Not an exothermic device
• Max Texh 625C (1150F) at Peak Torque
• Idle Texh 180C (360F)

Current Diesel Engine
DOC
DOC DPF

• DOC is exothermic for regen
• DPF filters stores PM
• Max Texh 650C (1200F) during Regeneration
• Idle Texh 180C (360F) except during regen

2007 Diesel Engine
DOC
DPF
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Maximum Exhaust Temperature 2007 Targets

• Skin temperatures
• Same as today
• Exit exhaust gas temperatures
• Not to exceed 400 C (750 F)