In accordance with EPA and EU standards, Manitowoc is re-engineering its cranes to incorporate the use of Tier 4i/Stage IIIB compliant engines. Both Cummins EGR and Mercedes SCR engines are used throughout the Grove and Manitowoc product lines.


About Tier 4

Regulations
The Teir 4 Interim was put into effect on January 1, 2011 by the U.S. Environmental Protection Agency (EPA). Diesel engines in the 174 to 751 ( 130 to 560kW) power range must meet the following regulation standards: -2.0g/kW-hr Oxides of Nitrogen ( NOx) -0.02 g/kW-hr Particulate Matter ( PM)

Goal
As compared with the current Tier 3 and Stage IIIA emission standards, PM exhaust emissions are required to reduce by 90%, and NOx exhaust emissions by 45%.

To Date
NOx and PM have been reduced by 60 percent since the introduction of Tier 1 standards in 1996.

Solutions

The engines in our cranes use the latest technology to produce lower emissions. Manitowoc Cranes works with top manufactures such as Mercedes MTU and Cummins to provide engines that are reliable, strong, and efficient.

To meet the Tier 4 Interim standards, we have taken steps to equip our cranes with engines incorporating the following technologies:

  • Engines equiped with higher pressure fuel injection systems. This provides clean combustion.
  • Exhaust gas recirculation and selective catalytic reduction systems to reduce the NOx
  • Capability to burn Ultra Low Sulfur Diesel, producing a cleaner burn.
  • The usage of CJ-4 low ash oil. CJ-4 low ash oil can withstand higher temperatures.
Tier 4 Final Technology
Tier 4 Final will take effect in 2014. NOx levels will be reduced by using Selective Catalytic Reduction ( SCR) technology, which injects diesel exhaust fluid ( DEF), into the exhaust stream. This will convert the NOx to nitrogen gas and water. Another tank will be on the crane to carry the DEF. GMKs with Mercedes engines will be adding EGR technology. Engines in our GMK3055, GMK4100B, GMK4115, GMK4115L, GMK5115, GMK5135, GMK5165-2, GMK6300L, GMK6400 will be redesigned from their current Tier 4 Interim design to the Tier 4 Final design in 2014. The GMK5225 and GMK5275 will receive the Tier 4 Interim engine at the end of 2012.
Ultra Low Sulfur Diesel
The usage of ultra low sulfur diesel (ULSD) fuel is required to prevent erosion of the engine systems, and an improved engine oil ( Cl-4) is required to handle the increased soot and acid levels occurring with EGR
CJ-4
CJ-4 is the American Petroleum Institute (API) lube oil specification for engines using exhaust aftertreatment such as a Diesel Particulate Filter (DPF) and cooled Exhaust Gas Recirculation (EGR). Commonly known as low ash oil, it is more resistant to heat and leaves lower amounts of ash deposits when it does burn off during the combustion process.

Benefits

Experience the benefits of our Tier 4 cranes! Not only will they improve the atmosphere- they will also improve your business.

  • Maximized performance and fuel efficiency
  • High pressure fuel injection systems result in cleaner engines and improved engine response
  • Variable speed fan drives have been incorporated on select models to reduce noise emissions and increase fuel efficiency.
  • Cummins Tier 4 Interim engines are compatible with Biodiesel blends up to B20 ( as long as fuel does not exceed 15 ppm sulfur content)
  • Tier 4 Interim engine parts are fully supported by Cummins and Mercedes

Frequently Asked Questions

 

1. Which sulphur level is required?

Fuel sulphur levels for use in Tier 4i / Stage 3b engines is regulated to 15 ppm in the U.S. and 50 ppm in the EU. All engines installed in Manitowoc cranes are designed to operate with these sulphur levels. Use of fuels with sulphur level higher than recommended will cause emission levels outside of legal limits and could dramatically reduce engine life. Engine warranty could also be voided by not using the proper fuel.

2. Do I need more fuel for the new technology?

Precise numbers are difficult to provide as it will vary significantly based on the specific machine and duty cycle in question. Based on testing completed to date, fuel consumption with Tier 4i / Euro 3b equipped cranes is similar to or slightly better than an equivalent Tier 3 installation.

3. How much Urea do I need?

Our engine suppliers are estimating between 3-5% of diesel consumption.

4. Where is Urea available?

SCR and Diesel Exhaust Fluid (DEF or Urea) was introduced in the U.S with the 2010 On-highway engine emissions regulations; anywhere that diesel fuel is sold to the U.S. trucking industry you will likely be able to buy Urea today. It is also available thru the Cummins distribution network. In Europe on-highway trucks have been using Urea since Euro 4 regulations went into effect in 2006. Urea is currently available at most fuel stations through either pumping stations or in cans. The availability will continue to improve over time.

5. What technology will you use to achieve Tier 4 compliance?

The technology chosen is based on the selection of the best engine for the specific crane model and the market it serves. For most cranes sold to the North American market, engines will utilize EGR & exhaust filtration. For most cranes sold into the EU, the engines will utilize SCR technology.

6. Are Manitowoc dealers ready to support these products?

Manitowoc dealers, in conjunction with the service organizations of the engine manufacturers, are ready to service Manitowoc cranes no matter what emissions level or technology may be installed.

7. Will service parts and service intervals change with Interim Tier 4/Stage III B engines?

For Tier 4i, Cummins engines require regeneration of the DPF, and the DPF will also require an ash cleaning. Per Cummins, ash cleaning interval is 5,000 hours.
The Mercedes option does not require service intervals for the DPF, but does require maintaining adequate Diesel Exhaust Fluid (DEF) levels. Estimated fill interval of the DEF is approximately every x fills of the diesel tank.

8. Will Tier 4 equipment uptime remain the same as Tier 3?

Yes. Cummins Tier 4 field test program has demonstrated that their Tier 4 Interim engines are able to achieve the same very high level of uptime availability as equipment powered with current Tier 3 engines.

9. What is the life of the Cummins Particulate Filter?

The Cummins Particulate Filter is designed to last the life of the engine. The aftertreatment is specially designed against high levels of vibration and shock loading.

10. Is low ash lube oil required for Tier 4?

Yes. To maintain regulated ash cleaning intervals it is strongly recommended to use API CJ-4 low ash lube oil in North America and equivalent ACEA-E9 lube oil in the EU.

11. How will engines with EGR and SCR technology affect me as an end-user?

The operator should notice no significant difference in operation of the crane if DPF and DEF systems are adequately maintained. The DEF system must maintain adequate levels of urea and the DPF system must be occasionally regenerated either actively or passively. Failure to maintain either of these systems will result in temporary decreased engine performance until the system is serviced.

12. How does this effect my existing equipment? Do I have to do anything to make them compliant with Tier 4 / Stage IV emission regulations?

Existing equipment is not mandated to change Tier levels due to the Tier 4i/Stage 3b emissions regulations. Repowering (replacing an older engine) a crane can also be done at the same Tier level as the original installation with no consequence. Some local regions, however, have implemented other regulations that may incentivize equipment owners to update existing equipment. It is important to know the laws in effect for each locality your equipment will be operating in.

13. What is the opinion of the Tier 4 field test operators?

Our test operators have been positive regarding the performance of the new Tier4 cranes; they have not had to do a manual regeneration on any of the tested equipment, and they have noticed no discernable difference in operation during re-generation. On crawler cranes, the reduced noise level (due to the VS variable speed fan) of the machine has been noted by not only the operator, but also by those working in close proximity of the machine. Operators have noted that the exhaust fumes have a different smell as compared to previous models.

14. How is the Cummins Particulate Filter serviced?

The Cummins Particulate Filter must be removed and cleaned by a Cummins-approved cleaning method and authorized technician. The ash cleaning process typically takes 30 minutes, plus the time to remove the Cummins Particulate Filter from the equipment.

15. What is regeneration and how does it affect me as an end-user?

Regeneration is the process of cleaning the Diesel Particulate Filter by increasing the exhaust temperature to a point where the PM that has collected in the filter media “burns off” and converts into ash. During this process, the exhaust temperature is elevated above normal levels. Most times, this process will happen undetected to the operator. A regeneration event is indicated by a dash light in the operators console. No other interaction is required.

16. Can I prevent regeneration from occurring?

Yes. In the operators console there is an inhibit switch which dis-allows a regeneration from occurring. This should only be used when absolutely necessary as the Diesel Particulate Filter will not have any ability to clean itself in this state. If operated in this mode for extended periods of time, the filter could become plugged resulting in reduced engine performance.