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1100 Series

1100 Series. Designed to perform… …delivered with choice. 1100 Series. 1103C. 1104C. 1106C. 1103 Mechanical. 1103C-33 3 cylinder 3.3 Litre Naturally Aspirated 1103C-33T 3 cylinder 3.3 Litre Turbo Charged. 1103C. 1104 Mechanical. 1104C-44 4 cylinder 4.4 Litre

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1100 Series

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  1. 1100 Series Designed to perform… …delivered with choice

  2. 1100 Series 1103C 1104C 1106C

  3. 1103 Mechanical • 1103C-33 • 3 cylinder • 3.3 Litre • Naturally Aspirated • 1103C-33T • 3 cylinder • 3.3 Litre • Turbo Charged 1103C

  4. 1104 Mechanical • 1104C-44 • 4 cylinder • 4.4 Litre • Naturally Aspirated • 1104C-44T • 4 cylinder • 4.4 Litre • Turbo Charged • 1104C-44TA • 4 cylinder • 4.4 Litre • Charge Air Cooled 1104C

  5. 1104 Electronic • 1104C-E44 • 4 cylinder • 4.4 Litre • Naturally Aspirated • 1104C-E44T • 4 cylinder • 4.4 Litre • Turbo Charged • 1104C-E44TA • 4 cylinder • 4.4 Litre • Charge Air Cooled 1104C

  6. 1106 Electronic • 1106C-60TA • 6 cylinder • 6.0 Litre • Charge Air Cooled 1106C

  7. 1100 Series 37-42 (49-56) 48-55 (65-74) 48-64 (65-86) 60-85.7 (80-115) 75-104.4 (100-140) 75-129.5 (100-174)

  8. 1103 / 1104 Mechanical Design Features Peripheral Fixed, Isolated Top Cover Eliminated Leaks Cross Flow Cylinder Head Performance, Emissions Integrated Closed Circuit Breather Delphi DP200 Fuel Pump Electric Lift Pump Leak Free/Durability Integral Oil Cooler No Leak Paths High Contact Ratio / Gear Train Reduced Noise Integral Rear End Oil Seal Stressed Block Reduced Noise Open Top Deck Block Reduced Noise, Improved Cooling Sump Edge Moulded Carrier Gasket, Leak Free

  9. 1104 Electronic Design Features Peripheral Fixed, Isolated Top Cover Eliminated Leaks Integrated Closed Circuit Breather Cross Flow Cylinder Head Performance, Emissions Electric Lift Pump Leak Free/Durability 12/24 Volt Bosch VP30 Performance, Emissions, Power Trim Integral Oil Cooler No Leak Paths Integral Rear End Oil Seal Eliminated Oil Leaks High Contact Ratio / Gear Train Reduced Noise Open Top Deck Block Reduced Noise, Improved Cooling Stressed Block Reduced Noise Sump Edge Moulded Carrier Gasket, Leak Free A4E1 ECM Power Set to + 3% on all Electronic Ratings Electronic FIE

  10. 1103C • 3 cylinder • 37 - 55 kW (49 - 74 hp) • Cross flow head • Identical front and back-ends to 1104 • “Family concept” key deliverables • Mechanical FIE only • NA / T models • Options from 900 Series and 1104

  11. 1103C Product Highlights • 22% increase in capacity to 3.3 litres • 15% increase in power to 55 kW (74 hp) • TBU increased to 25% turbocharged, 22% on naturally aspirated • Torque at 1000 rpm increased by 13% • 500 hour service intervals • True family installation and service with 1104

  12. 1104C • 4 Cylinder • 48 – 104.4 kW (65 - 140 hp) • Mechanical and Electronic • Choice of NA, T, TA aspirations • Improved low speed torque and torque back up • Cross flow cylinder head • Noise / Quality / Service improvements

  13. 1104C Product Highlights • 4.4 Litre New Architecture • Performance improvements for example: • Power increased to 97 kWm (130 hp) • TBU increased to 30% • Peak torque increased by 10% • Torque at 1000 rpm increased by 37% • 3 dBA quieter • Installation envelope as New 1000 • Full authority electronics an option • 500 hour service intervals

  14. 1106C Design Features Peripheral Fixed Aluminium Top Cover Eliminated oil leaks No Leak off Rail Injectors Eliminates Leak Off Rail Multi-Piece Exhaust Manifolds Improved reliability Carrier Joint Oil Cooler Cover Seal Eliminating oil leaks Optimised Swirl Combustion System Emissions / Performance Integral Rear End Oil Seal Eliminated oil leaks 12/24 Volt Bosch VP30 Performance, Emissions, Power Trim A4E1 ECM Power Set to + 3% on all Electronic Ratings High Contact Ratio / Gear Train Reduced Noise Tappet Chamber Barriers Oil Carryover

  15. 1106C Product Highlights • An evolution of previous 1006 Engine • Full authority electronic control • 75 to 129.5 kW (100 - 174 hp) • Improved quality • Reduced noise

  16. 1106 Product Highlights • Installation envelope as previous 1000 Series • TBU increased up to 35% • Torque at 1000 rpm increased by 20% • Noise reduction of 1 dba • Air/Air charge cooling and electronics • 500 hour service intervals • Easy first step to electronics

  17. Voice of the Customer Importance Ranking Summary of Sub-Categories 1. Reliability 16. PTO 2. Quality 17. Speed 3. Cost of Engine 18. Design Installation 4. Product Availability 19. Electronics 5. NVH 20. Cold Starting 6. Product Support 21. Low Speed / Idle Requirements 7. Service 22. Governing 8. Cost of Operation 23. Fuel Tolerance 9. Rated Power 24. Emissions 10. Torque Curve 25. Environmental / Green Issues 11. On Time Delivery 26. Package Cost 12. Durability 27. Image / Branding 13. Cooling System 28. Weight 14. NPI 29. Protection 15. Package Flexibility 30. Safety and Integrity 31. New Concept • Productivity • Reliability • Cost of Ownership

  18. 1100 Series Productivity:

  19. Productivity • Improved Customer Productivity? • Capital Investments £M • Design Features, and Robust • Enhanced Flexibility of Products and Services • Expanded, Even More Flexible offering

  20. Manufacturing Key Objectives • Maintain competitive product position • Deliver a step improvement in product quality and reliability • £30 million investment programme, driven by... Customer value, Quality and Reliability

  21. Quality Improvements • APQP - Advanced Product Quality Planning • FMEAs (Failure Mode & Effect Analysis) • Poke Yoke(Designed for assembly) • Outsourced Sub-Assemblies • Reduced routine Complexity • Increased focus on customer specifications

  22. Low Speed Torque More Low Speed Torque 1100 Series Engine Torque Stage I Engine Speed (rpm) 1000 2200

  23. 1100 Series Refinement

  24. Engine Noise Reduction • Significant Noise Reduction over speed and load range • Charge Cooled 1104C • Full load range, over3.5 dB(A) reduction • 90.8 dB(A) at 2200 rev/min - previously 95.5 dB(A) • Naturally Aspirated 1104C/E • Full load range, over2.5 dB(A) reduction • 92.0 dB(A) at 2200 rev/min - previously 94.5 dB(A) 1100 Series 34% 1100 Series 58% (Numbers quoted being average Sound Pressure Level at 1m, dB(A) re. 20 Pa )

  25. Engine Noise Reduction • At Idle - an important subjective condition • Naturally Aspirated 1104, 3 dB(A) reduction 82 dB(A) 1100 Series 50% Reduction 50% (Numbers quoted being average Sound Pressure Level at 1m, dB(A) re. 20 Pa )

  26. Engine Noise Reduction In Vehicle • At Typical Vehicle Legislation test Conditions • Naturally Aspirated 1104 3 dB(A) reduction • 94 dB(A)  91 dB(A) • Vehicle Noise Benefits already achieved 1100 Series 50% Reduction 50% (Numbers quoted being average Sound Pressure Level at 1m, dB(A) re. 20 Pa )

  27. 92.4 dBa 97.0 dBa 90.0 dBa NoiseSituation Comparison - Sound Pressure dBa

  28. 1104 Noise Refinement • Two piece pressed steel • Sound deadened material • Reduces noise • New Gear Tooth Profile • Closer gear contact – tighter helix • Reduced noise • Open Top Deck Block • Reduces noise & vibration transmission • Prevents bore distortion

  29. Peripherally Fixed Top Cover • Integral Seal in Top Cover (‘O’ Ring) = Leak Free design • Reduced vibration and noise transmission • Inclusion of injector cover 1104 Peripherally Fixed Top Cover

  30. 1100 Series Low Cost of Ownership

  31. Low Cost of Ownership Extended Warranty Reduced oil consumption Extended service intervals Cost of Ownership Fuel economy Ease of service Parts support Durability and reliability

  32. Low Cost of Ownership • 1100 Series focus is through • Reduced oil consumption • Ease of service / extended service periods • Ease of installation • Improved peace of mind - two year warranty Improved fuel economy

  33. 1104C v New 1004 at FLRS 1104C v New 1004 at Max Torque So far … with new head improvements to come 230 250 240 220 SFC (g/kWh) SFC (g/kWh) 230 210 220 200 4NA 4T 4TW/4TA New 1000 1104C 1104NA 1104T 4TW/4TA New 1000 1104C Low Fuel Consumption

  34. 12/24 Volt Bosch VP30 Performance, Emissions, Power Trim Cross Flow Cylinder Head Performance, Emissions High Contact Ratio / Gear Train More accurate FIE Reduced Noise Electronic FIE Accurate Fuel injection Low Fuel Consumption • Cross Flow Cylinder Head • Increased air volume & flow • Lower fuel consumption • Low cost of ownership

  35. Improved Fuel Economy Fuel Economy • At specific conditions • Across operating range of engine • As in improved fuel economy by 1-6% Through • New cylinder heads (cross flow on 3, 4) • New FIE • Electronics

  36. 1104 and 1104 Cylinder Head Inlet Manifold Cross Flow Head

  37. Fuel Injection Equipment Delphi DP200 Mechanical Fuel Pump Bosch VP30 Electronic Fuel Pump

  38. Low Cost of Ownership • 1100 Series focus is through • Improved fuel economy • Ease of service / extended service periods • Ease of installation • Improved peace of mind - two year warranty Reduced oil consumption

  39. Reduced Oil Consumption Oil Consumption • Halved 3 and 4 cylinder Through • New block structure • New bore finish

  40. 1103 / 1104 Block Design Cylinder Finish NEW 1000 Series 1100 Series Open Top Desk Block

  41. 1104C Oil Consumption • Reduced need to refill • Wider Max and Min Mark • Larger sump

  42. 1106C Oil Consumption • 1106 (Stage 2) Target: <0.2% • 1006 (Stage 1) target : <0.2%

  43. Breather Oil Carry overThe 1106 Solution 6 cylinder Tappet Chamber Barrier

  44. Breather Oil Carry overThe 1106 Solution • All models • Tappet chamber barriers - 50% reduction in oil carry over • Closed circuit breather option • New high efficiency CCB system • Reduces oil carry over to 2g/hour • No turbo, ATACC fouling or manifold leakage

  45. Oil Consumption and Carry over Summary • How? • New honing process • Open top deck • Piston ring pack development with suppliers • Benefits • Lower cost of ownership • Increased customer confidence

  46. 1104C Oil Consumption Benefits • Extended service intervals – 500 hour oil change • Low cost of ownership • Increased productivity

  47. 1104C Oil Consumption • 1104 New Open Top Deck Block Structure New 1000 Series • Finer honing • Improved Oil Flow • Lower Oil Consumption 1100 Series Peripherally Fixed, Isolated Top Cover Eliminated Leaks Integrated Closed Circuit Breather Electric Lift Pump Leak Free/Durability Integral Oil Cooler No Leak Paths Sump Edge Moulded Carrier Gasket, Leak Free Integral Rear End Oil Seal

  48. Stage 2 Product - Improved Open Breather Performance • New engine architecture • Stable open deck block design • Consistent bore geometry • New piston design • New bore honing process • Reduced blow by and oil carry over • Evidence obtained via >100,000 test bed hours and >41,000 machine hours

  49. Oil Carry Over (gr/hour) New 1000 Series 1100C Full Load Rated Speed 15-20 2 70% Load Factor 1.5 0.24 Oil Carry OverImproved Performance • Approx. 90% of carry-over is oil vapour (visible smoke) • 10% is liquid oil • Oil carry over is measured in grammes/hour • 1100C benefit: • Total oil content within the air mass has reduced by up to a factor of ten.

  50. Blowby (litres/second) New 1000 Series 1100C Full Load Rated Speed 0.8 0.6 70% Load Factor 2 0.8 Blowby Gases Improved Performance Blowby is measured in litres/minute Blowby is measured using conventional airflow measuring equipment • 1100C benefit: • Crankcase blowby gases reduced

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