Stage V Engines

Stage-V engine Family

448- 97 & 112kW 430- 55kW

CEV Stage-V Engine Emission Standard

For concept understanding only

CEV-IV Stage V 3L :Engine and ATS
Engine Specifications
Engine Unit 3L CEV-V 4.4L CEV-IV

Rating kW@ rpm 55@ 2200rpm 55@ 2200rpm

Torque Nm 440@1200rpm 400@1200rpm

Bore mm 92 103

Stroke mm 112 132

Compression Ratio Ra 16.5:1 16.7:1

Engine ATS:DOC/DPF
Displacement Litre 2.98 4.4

Features: Firing Order 1-3-4-2 1-3-4-2

1. Compact Engine
2. HLA – Hydraulic Lash Adjuster CRDi+EGR+DOC+
Combustion System CRDi+EGR
DPF
3. Glow Plug – Cold start Aid
4. Low fuel consumption compared to CEV-IV
5. Improved fuel filter life
 Full Load Torque Curve - Overview

450

400 4.4l_55kW
.xlsx [Logs] CorrTorque [Nm]
.xlsx [Logs] CorrTorque [Nm]
3L_55kW
350
Corr Torque [Nm]

300

250

200

150

100

50
800 1000 1200 1400 1600 1800 2000 2200 2400
speed_Engine [rpm]

Compact Engine, +40Nm Peak Torque

For concept understanding only
3L Engine Major part list

10

3 13
12
1
11
6
5
4 9

2
8

S. No Part Description S. No Part Description S. No Part Description

1 Block 6 Flywheel Housing 11 HP pump
2 Bedplate 7 Fuel Filter Main 12 Common Rail
3 Cylinder Head 8 Fuel Filter Second 13 Wiring Harness
4 Crankshaft 9 Gears # 4 No,s 14 Starter Motor
5 Camshaft 10 SVA Injector – DTVS 15 Intake Throttle Valve
430 Engine top view

CCV breather Pipe

EGR Actuator

SEG 3.5kW Starter motor Engine ECU

E actuated-Turbo Charger EGR Cooler

Crank case ventilation
venturi pipe
Turbo Actuator
Intake Throttle Valve
Intercooler outlet temp
sensor
430 Engine Side View

MAF Sensor
Turbo charger Intake throttle Valve
Coolant Temp Sensor

Oil filter

Alternator 105A

Water pump pulley

Auto Tensioner

Crank shaft Pulley

Main fuel filter(2 Micron)

Oil level sensor
430 Engine Side View

ITV Actuator
EGR Valve Actuator

EGR Cooler

Oil filter IMV-Inlet metering Valve

New HP pump

Fuel Temp Sensor

Main Fuel filter

430 Engine Side View

Glow plug

Turbo oil feed pipe

Crank case Turbo oil drainpipe

ventilation hose
Coolant inlet

Flywheel Housing
Hydraulic Lash Adjuster
Load due to the valve Spring Load transferred
actuation to the HLA

Controlled oil
leakage
Oil flow Oil flow
HLA collapsing
Plunger in contact
≈ 0.1 mm
HLA recovers the with the body →
Check valve is HLA at bottomed
closed working position
and check valve position
closes

After engine turn-off some position will be

under-load (valve open).
• Spring load transfer through the rocker arm to
Valve event the HLA makes it collapsing gradually till
Came base circle • Motion transferred from cam to the valve Restored cam base circle reaching the bottomed condition. When HLA is
HLA assembled in the engine. via HLA/pushrod/rocker arm. • No load due to the actuation. at bottomed there is a consequent partial valve
• No load due to the actuation. • Load resulting from the actuation acting on • Plunger spring restores the HLA working closure (valve displacement = rocker ratio X
• The HLA is at the working position the HLA. • HLA collapsing in the order of ≈ position. HLA dry lash).
due to the valvetrain layout, showing a 0.1 mm. • Check valve open, oil flow from the low- • After few cycles HLA restore the normal
certain dry lash (available stroke), • Check valve closed. pressure chamber to the high pressure operation. During this transient the valve close
generally in the order of 1.5 – 2 mm • Oil controlled leakage through the coupling chamber. with higher velocity with respect the standard
(after stabilization time). surface between body and plunger • Check valves closes. operation.
Engine ECU DCM 7.24

Header construction: Right angled PCB Mount – Uncoded

Number of pins on Vehicle side 91
Number of pins on Engine side 105 Barometric pressure sensor
Surface coating Tin
Total number of pins 196
C_CAN_1_H Pin V81
C_CAN_1_L Pin V80
C_CAN_2_H Pin V77
C_CAN_2_L Pin V78
C_CAN_3_H Pin E79 & V14
C_CAN_3_L Pin E80 & V15
EGR: Exhaust Gas recirculation
Actuator Sensor Pin Out Wire ECU Pin
No No
1 – Supply (5V) 5901 51
2 – Ground 6902 10
3 – Signal 5903 94
4 – Motor (+) 5906 68
5 – (Not used) - -
6 – Motor (-) 5904 89
Gear Train
CEV-IV 444 & 448 & CEV-V 448 CEV-V 430
FIP Camshaft Idler HDPTO

Oil Pump Crank shaft

430 Engine Fuel System
Suction pressure(0.6-2bar)
HP pump return line pressure(<1.3bar)
Inlet pressure(5-7bar) Common Rail
Fuel return line pressure(5-7bar) Injector Leak off -line
High pressure line(350-2000bar)

HP Pump
Main Fuel Filter

WS
Fuel temp
Primary filter + Fuel Cooler Sensor
Electrical lift
pump assembly

Fuel Tank
Fuel Circuit
A- ECM (Engine Control Module)
B-High Pressure Pump
V
C-Common Rail
D-Fuel injectors
E-Fuel filter
F-Fuel lift pump with pre-filter & water separator
G-Fuel tank
H-IMV (Inlet Metering Valve)
J-Fuel rail pressure sensor
K-TMAP sensor
L-Camshaft position sensor
M-Crankshaft position sensor
N-Coolant temperature sensor
P-Exhaust manifold temperature sensor
Q-Exhaust manifold pressure sensor
R-MAF (Mass Air Flow) sensor
S-Throttle position sensor
U
T-Fuel Temp Sensor
U-Fuel Cooler
V-HPV
HP PUMP
No Name No Name
1 Housing 5 IMV

2 Front plate 6 Inlet connector

3 Hydraulic Head 7 Back leak connector

4 Drive shaft 8 High Pressure Outlet
3L: Fuel Filter
PRIMARY FILTER ( 5 Micron)
FILTRATION EFFICIENCY
97.0 % @ 4 µm
99.5 % @ 6 µm
100.0 % @ 14 µm
Coalescer Media.

SECONDARY Filter (2 Micron) :

FILTRATION EFFICIENCY
99.0 % @ 4 µm
100.0 % @ 6 µm

Make: Donaldson

SECONDARY FILTER
(1000 hrs)

PRIMARY FILTER No water present > 180,000 Ohms

( 1000 hrs) Probe submerged in water 0 – 60,000 Ohms
Operating pressure 5.75 ± 0.5bar
Expected free flow delivery 2.58L/min at 0bar
Tool to remove
the filter

Tool to remove
the filter
Lift pump filter port Identification
Glow Plug

• All 4 glow plugs are located above the exhaust manifold

and are adjacent to each injector.
• The main function of glow plug is to heat the air inside
the combustion chamber. Glow plug
• This heating of air helps in starting where the
temperature is way below 0-degree Celsius.
Note: Glow plugs will not be in operation above -4˚C
430 55Kw Stage 5 After Treatment
• DOC • DPF

DPF = Diesel
Particulate Filter

DOC = Diesel
Oxidisation Catalyst
After Treatment Sensors
Delta P Sensor

DOC Temperature Sensor Delta P Sensor Ports

(Inlet and Outlet)

DPF Temperature Sensor

ATS Can Specification - Overview

For concept understanding only

Integrated Single Can Assy : 7.5” X 12” 4”DOC+8” DPF

What’s New in Stage-V
MAF sensor fitted on turbo inlet Automatic Valve lash adjuster

In loop Crank case ventilation In loop Crank case ventilation

•A - Boosted Air Pipe

•B - 2mm Nozzle Adaptor

•C - Crank Case Impactor

•D - Crank Case Venturi Pipe

•E - Vent to Atmosphere
•F - Inlet Adaptor
Component Identification
E-Wastegate Turbocharger

• Replaces VGT. Not Canbus

• Turbo replacement set up only performed on a
new unit – through SM4
• Setting up an old worn turbo will fail and a new
actuator would be required
• Removal of EGR gives simplified air flow
management so no need for VGT
• Is proportional with position sensor built in
Stage V Engine – Sensor Locations
E actuated
Turbo
HPV connector
Coolant
Temp Fuel Temp

Fuel Rail Inlet Metering

Pressure Valve (IMV)
sensor

Knock
Sensors Cam Sensor

Oil pressure
Crank Sensor
Oil Level
Stage V Engine – Sensor Locations

Temp &
Manifold
Absolute
Pressure Exhaust
Temp
HPV

Exhaust
Manifold
Pressure
430 55kW Stage 5 After Treatment
DPF = Diesel Particulate Filter

DOC = Diesel Oxidisation Catalyst

Soot rich
exhaust gas

Filtered
exhaust gas
DOC and DPF Structure

• DOC consists of Honeycomb Type substrate structure inside

• DOC and DPF structure will have following major constituents
• Substrate
• Wash Coat
• Support Mat
• Overall Canning
DOC Specification
DOC Specifications

DOC

• Diesel Oxidation Catalyst (DOC) –

 Purpose of DOC is to oxidize the HC and CO coming
from the Exhaust and form H2O & CO2
 Support for Increasing the upstream temperature of
DPF
 Used to convert NO to NO2 which supports in
Passive Regeneration
For concept understanding only
DPF Specifications
DPF Specifications

DPF

• Diesel Particulate Filter (DPF)

• Diesel Particulate Filter helps in filtering out the Particulate matter which is coming from
the Engine Exhaust

For concept understanding only

DPF – Diesel Particulate Filtration

- Plugged Inlet Channels act as outlet channels for exhaust flow

- Plugged Outlet channels act as inlet channels for exhaust
For concept understanding only flow
Why we need to Regen.
• A regen will burn off soot but not ash. Soot in
• Soot (PM) burns off at >320ºC during normal operation due to spare NO2 DPF
and at 600ºC during a thermally managed regen.

• A blocked DPF can cause an uncontrolled burn at temperatures of between

1000 and 1400⁰C
• Keep engine and exhaust area free of debris at all times
• Ensure all exhaust joints are sealed during inspections
• If this happens, a regen wont burn it off. You will need to physically remove or
replace.
Soot Vs Ash
• Soot is primarily composed of Carbon, but also contains other
hydrocarbons from fuel and engine oil, sulphates and small
amounts of ash
• Soot is in dark colour
• Soot can be removed by regeneration process
• Ash is in lighter colour
• Ash is primarily composed of metallic components which are
incombustible in nature
• Many sources cause ash formation but majority of ash originates
in engine oil
• Ash remains inside the DPF, and specialized cleaning process is
required for Ash removal from DPF
• Soot agglomerate ~ diameter 0.1 µm(microns)
• Ash agglomerate ~ diameter 5 µm
• Ash particles grow and agglomerate to a size of 1 to 10 µm

Use of correct Engine Oil is very important for DPF life

For concept understanding only
Service Schedule(3L)
filter Elements Part No
Service Category Change Period
Service Part change Part No
Transmission Oil Filter Interval
581/18063 Machine 100/500
CEV-IV
Hydraulic Oil Filter element
Oil (CK4) 4001/3700 500 40/300893 Machine 100/500
schedule to be
Engine Oil Filter 320/C4114 Engine 500 added
Oil filter 320/C4114 500
Primary fuel filter element 320/A7406 Engine 1000
Main Fuel filter Element
Fuel Pre filter(5 micron) 320/A7329 1000
320/A7331 Engine 1000
Main Element(Outer) 400/17182 Machine 1000
Safety
Final fuelElement(Inner)
Filter(2 Micron) 320/A7331 1000400/17183 Machine 2000
Hydraulic Suction Stainer 335/Y7276 Machine 4000
Coolant change No change
Hydraulic Suction Stainer ( Steer) 2000335/Y7275 Machine 4000
Description Current Part No Category Change Period
Air filter Primary 400/17182 1000
Engine Oil CK4 – HL Engine oil Engine 500
Air Filter Safety
Transmission Oil 400/17183 2000Same As Stage IV Machine 1000
AxleHydraulic
Oil Filter
Same As Stage IV Machine 1000
Hydraulic Oil Same As Stage IV Machine 4000
Hydraulic Oil change
Coolant Same As Stage IV Engine 4000
Regen

1) What is a regeneration?

Regeneration is the process of removing soot from the DPF, it uses heat to burn off the soot, leaving a small amount of
ash in the DPF.
DPF Regen
3) How often will a regeneration be required?

The engine will try to remove soot from the DPF during normal machine operation, either through the normal duty
cycle of the machine or by adding additional fuel via post injection into the combustion cycle to elevate exhaust
temperatures and burn off the soot. If the engine cannot remove sufficient soot by itself then a manual regeneration is
needed by the operator. The frequency of DPF regeneration will be dependent upon:

1. Machine duty cycle

2. Engine run time
3. Number of interrupted regenerations
4. Environmental conditions
Regeneration Types

• Automatic Passive Regeneration

• Automatic Active Regeneration
• Manual (Stationary) Regeneration
• Service Regeneration
Regeneration Types
Automatic Passive Regeneration –
• Performed during normal duty cycle without interference
from engine ECU
• Requires sufficient exhaust temperature and air flow
• Typically works above 316⁰C
• HEST (high exhaust system temperature) lamp will HEST Lamp
illuminate if temperatures reach >450⁰C
Regeneration Types
Automatic Active Regeneration –
• If Passive cleaning is not performed due to low duty cycle, this will
be performed periodically
• Temperature increased with fuel injection on to DOC
• HEST lamp will illuminate only when the exhaust is hot enough
Regeneration Types
Manual (Stationary) Regeneration –
• If Auto-refresh does not clean sufficiently or the inhibit button is used for long
periods, then this must be performed
• The ‘refresh’ symbol will appear, and the operator will have to perform this regen.
before a torque and speed derate is applied
• The procedure and pre-requisites may vary for different machines so always
check the operator’s manual
Regeneration Types
Manual (Stationary) Regeneration (continued) –
Preparing the machine for a stationary refresh;
1. Ensure machine is stationary
2. Parked outside
3. In neutral
4. Park brake ON
5. Hydraulics isolated
6. Engine running

• Once the ‘entry’ conditions have been met, press the refresh button for 10 seconds
• Refresh lamp will flash to indicate the cycle has now commenced
• If the lamp fails to flash repeat the process checking the ‘entry conditions’
• Regen. will take up to 60 minutes to complete
Regeneration Types
Manual (Stationary) Regeneration (continued) –
• A flashing lamp will appear when regen. starts
• The stationary refresh cycle will stop if the inhibit button is pressed or the ‘entry’ conditions change
• The refresh lamp will remain displayed until the manual refresh has been successfully completed
• The ‘engine’ lamp will flash on start up for 30 seconds if the manual refresh is overdue
• After a set time the lamp will be displayed ‘solid’
• This indicates the engine has gone into a de-rate
• A final DPF derate will restrict the engine to idle - more severe than an SCR derate
Regeneration Types
Service Regeneration –
• Performed only using SM4
• Procedure lasts for approximately 45 to 60 minutes
• Red lamp will flash while regeneration is being done
• A service regen. can be performed without the
machine asking for one;
o If a high security unlock code is requested on JDS
o Must use serial number that matches ECM
o For one-time-only unlock code
• Change engine oil and filter after a service regen.
DPF Capacity Reduction
Service
110 Cleaned or
Manual Replaced &
100 Reset on SM4
90
Passive & Automatic
80
70
DPF Blockage %

60
50
40
30
20
10
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000

Engine Hours
Notes for regen. graph
• Only regens down to 20% as last of soot takes too long to burn off and it
improves the filtration within the DPF (30% on a JCB 430 engine)
• The 20% line will effectively become the new ZERO % once a regen is
completed
• Reduced time between regens above 2000 hrs as ash starts to build up
• Passive and Automatic regens occur approximately every 30-80hours depending
upon load cycle (initially – reducing as ash build up)
Notes for Regen. graph
• More frequent regens could be an indication of;
 Low duty cycles
 Excessive idling
 Too many stop / starts
• Premature blockage could be due to;
 Wrong fuel –Low grade and high Sulphur fuel
 Wrong oil (Only CK4 oil to be used)
• A clean (removed from machine) involves high frequency vibrations as air
is blown through the filter backwards. Recon DPF enable to replenish against
the blocked one as exchange.
SCR-F (DPF) Maintenance
Maintenance?
• Correct oil and fuel (CK-4 & ULSD. No blending)
• Operator to allow regens to occur
• Less idling / low duty cycles
• Operator to monitor regen. frequency and HEST lamp
• Investigate after-treatment fault codes (incl. datalog)
SCR-F (DPF) Maintenance
A blocked DPF results in;
• Fault Code
• Derates
• Higher back pressures
• Higher fuel consumption
• Power loss
• Exhaust blockage & failure
• Machine breakdown & requirement for new SCR-F(DPF)
Importance of Correct Oil and Fuel
• Sulphur in non-ULSD fuel will –
o Damage the HP fuel pump
o Damage the injectors
o Poison the DOC and SCR-F wash coating
• Non-low SAPS engine oil will –
o Prematurely block the SCR-F/ DPF
o Poison the DOC and SCR-F wash coating
• When heated to 200ºC for one hour –
o 40% of old mineral engine oil will evaporate
o 13% of CH engine oil will evaporate
o 6% of CI engine oil will evaporate
o 1% of CK engine oil will evaporate
• This burnt off oil will cause damage to the turbocharger and affect after-treatment efficiency
DPF Regen Strategy-BHL
After treatment system can

DOC DPF
Exhaust gas
Soot,
representative
picture
When soot reaches full 100%
Active Regen Manual Regen Manual Regen Service Regen
Passive Regen Temp.: ~550 C̊ Warning Temp.: ~550 ̊C
Temp.: ~550 C ̊
Temp.: >280 C ̊

Soot burn in the presence of Soot burn in the presence of

NO2 in the exhaust gas Soot burn in the presence of As manual regeneration not
O2 in the exhaust gas done
Continually calculated by the O2 in the exhaust gas
Automatic process triggered Triggered via Service master
ECU as part of the soot model Manual process triggered by
by the ECU based on soot
(all levels) customer input via CM1 CAN
loading or time interval
message.

Triggering condition: Triggering condition: Triggering condition: Triggering condition: Triggering condition:
Not applicable Soot level >105% Soot level >123%<128 Soot level >128% Soot level >130%
Time based:100 Hr Time based:119 Hr Time based:127 Hr

No operator interaction required Operator to evaluate Operator interaction required machine at

Machines runs normally to work harder static/Garage mode
Regeneration : Operator Guide BHL
DPF Regeneration
High Exhaust temperatures : HEST Symbol indicates machine is cleaning
the exhaust filters. It is not a fault, continue to use the machine.
High Exhaust temperature can be hazardous in a flammable
environment & may cause harm / damage to nearby objects.

Manual regeneration is required : Perform manual regeneration when

Regen tell-tale glows in display . If ignored the engine will de-rate and
operate with limited power and torque

To start the manual regeneration, park the machine in safe area and:
Apply park brake
Ensure engine is running
Select Neutral
Do not apply throttle
Manual Regen Regeneration Tell- Press the manual regen button for 10 sec – Engine speed will increase during regeneration & Regen tell-tale will start flashing.
Switch tale flashing Wait until tell-tale goes off & Engine rpm comes down to 850 rpm– Regeneration complete

Service Regeneration is required : Regeneration by the operator is no longer available and must be carried out under close
supervision by a dealer. Engine will derate significantly and machine can’t perform operations
Service Master
Service Master
Which components need resetting on a Stage 5 engine if they
are replaced?
Reset on SM4 if Replaced
1. ACM (DCU) After treatment Control Module
2. SCR-F (SCR loading to ACM and Soot loading to ECM)
3. E-wastegate turbocharger
4. NOx sensor/s
5. Delta P sensor
6. DEF dosing module (injector)
7. Fuel injector/s (and codes)
8. Inlet metering valve
9. High pressure fuel pump
10. Cam sensor
11. Inlet throttle valve