Compliance with the latest instalment of stringent European legislation governing diesel engine emissions has presented a serious challenge for manufacturers. Doosan Industrial Vehicle UK (DIV UK) believes it has risen to this challenge by bringing a true solution to the market, in the form of the G2 diesel engine. PBM’s Alex Juggins reports from the launch.
The new EU emissions standards covering diesel engines of non-road vehicles — including forklifts — have commanded widespread discussion among those in affected industries. PBM touched on the implications of the European Emission Regulations specifically for merchants in the July/August edition of the magazine, with Doosan’s Tim Waples warning that the standards could increase merchants’ costs in operating forklifts.
In short, Euro Stage IIIB of the Regulations applies to all diesel engines between 37 and 56kW, while Euro Stage IV apples to all diesel engines over 56kW. The Regulations require a 90% reduction in the NOx, HC and PM produced by such engines — clearly a significant departure from previous levels. With this in mind, manufacturers have had to get their thinking caps on, in order to design high quality diesel engines for the future.
With such huge reductions in emissions stipulated by the EU, this should surely necessitate compromises in diesel engines’ design and performance, at least in the short term? Not so, says Doosan. Indeed, it was against this climate of strict European legislation that the manufacturer recently launched is G2 range of engines, which meets the new standards without using a potentially costly diesel particulate filter (DPF).
Setting new standards for low fuel consumption, the award-winning G2 engine provides a unique solution at a time of sharply increasing costs for forklift users, claims Doosan.
Tim Waples, Director of DIV UK, explains: “With the new regulations requiring an enormous 90% reduction in emissions of gases and particulates compared to those they replace, a real challenge has been presented to engine manufacturers.
“Rather than the dated ‘sticking plaster’ solutions offered by others, we recognised that the regulations required a radically new and innovative approach to diesel fuel combustion within a forklift engine.
“To meet this challenge, our in-house engine division invested millions of pounds in producing an engine that can get the job done and comply with the latest emissions standards — and without the operator ending up out of pocket.”
Before being introduced to the market, the new engines were put through their paces in a series of rigorous tests at the renowned Millbrook Proving Ground which, incidentally, was also the venue of choice for the launch of the engines. Phil Stones, Head of Emissions and Fuel Economy at Millbrook, explained: “Millbrook is very pleased to have assisted Doosan with this important programme.
“Building on Millbrook’s previous working relationship with Doosan, we extensively tested the G2 diesel engine in the Variable Temperature Emissions Chamber (VTEC), followed by track tests to the Vehicle Dynamics Institute’s (VDI) standards, which resulted in a success for the programme and the product.”
Winner of the Innovation category at the FLTA Awards 2014, the G2 is said to have the lower fuel consumption, longer maintenance intervals and maintenance-free after-treatment systems that reduce the total cost of ownership over the life of the engine. This means the payback period is faster than for any other engine in this class. This was an important factor for many of the attendees at the launch event, with a host of suppliers and merchants indicating that their first impressions of the engine were positive.
Using Diesel Oxidation Catalyst exhaust treatment technology, along with an Exhaust Gas Recirculation system, the new range of ‘DPF free’ engines is available in 2.4-litre and 3.4-litre versions. In tests at Millbrook Proving Ground, the smaller engine recorded some of the best fuel consumption figures ever seen in the forklift industry. Fuel consumption was reduced by more than 30% to as little as 2.09-litres per hour in standard mode and 1.67 litres per hour when the optional speed limiter is deployed.
The more powerful version has three different power outputs — 55k, 74 and 82kW — to suit every application. All the engines exceed the regulations and maintain performance, while ensuring that Doosan products remain cost-effective to purchase and run, as well as being among the most environmentally friendly available.
Tim Waples firmly believes that “the G2 engine represents a watershed moment in forklift diesel engine design. It is a genuinely innovative approach to the challenge of maintaining performance while meeting exacting emissions standards and will become the benchmark engine against which all others in the market are measured.”