2 VCR Presentation Product MGMT - May 2013 - V1

Two Valve Common Rail (2VCR) Engine
Technology
Comparative Analysis
MAN [Company] [optional: Brand] Author Current topic 00.00.2012 < 1 >
Engine Specifications
SN. Parameters 2 VCR (New Engine) VP44 (Existing Engine)

D0836LFL08
1 Engine Model D0836LFL13
2 Engine Type 6cylinder , Inline ,Vertical 6cylinder , Inline ,Vertical
3 Combustion System DI , TC IC DI , TC IC
4 Valve per Cylinder 2 2

Bosch Common Rail System Unit Bosch Rotary Pump Unit with
5 Fuel Injection System
with Electronic Diesel Unit Electronic Diesel Unit
6 Rated Power 206kW /280hp at 2400 rpm 206kW /280hp at 2400 rpm
7 Max Torque 1100 Nm at 1300 – 1700rpm 1100 Nm at 1300 – 1700rpm
8 Min Bsfc 198 g/kW-hr 198 g/kW-hr
9 Torque Back Up 0.34 0.34
10 Low Idle Speed 600 rpm 600 rpm
11 High idle Speed 2650 rpm 2650 rpm
Electronic Diesel Control ;

Electronic Diesel Control
12 Governing (EDC) and Power Train Manager
(EDC)
(PTM)
13 Emission Compliance Bharat Stage –III (Euro-III) Bharat Stage –III (Euro-III)
MAN Trucks India Pvt. Ltd. CLA Raju Ghandas 2VCR – Product Management 15.05.13 < 2 >
Working of 2VCR Engines
Structure and operation of the common-rail system
 Efficient combustion is only possible if there is good mixture formation. This is where the injection system plays
such a central role. The right quantity of fuel must be injected at the right time and with a high pressure.
 The common-rail system is a trend-setting high-pressure injection system which involves the separation of
pressurization and injection. The fuel for the individual cylinders comes from a shared accumulator (rail) which is
constantly kept at high pressure. The accumulator (rail) is pressurized by a high-pressure pump. This pressure can be
changed to suit the operating conditions in question
 Each cylinder is equipped with an injector which is controlled by a solenoid valve. The injection quantity is
determined by the outlet cross-section of the injector, the solenoid valve opening duration and the accumulator pressure.
 Separation of the pressurization and injection functions allows a better injection characteristic and therefore,
improves combustion development. Multiple injections, i.e. pre-injections and post-injections, are possible. The fuel
quantity, start of injection, pre-injection and post-injection are controlled by extremely fast solenoid valves.
Common Rail System
1 – Injectors
2 – Rail (Accumulator)
3 –Tank
4 – High pressure pump
5 – Fuel filter module
6 – EDC 7
7 – Sensors and actuators
Common Rail System
(Make: BOSCH)
Features:
• Bosch System, 1600 bar working pressure
• Heavy duty Solenoid operated Injector
• High Pressure pipes suitable for higher system
pressure
Advantages:
• Multiple Injection possible for Controlled Combustion
resulting in lower noise and higher Efficiency
• Higher Injection Pressures irrespective of Engine
RPM – Better Low speed and Part load efficiency.
Benefits:
• Fuel Pressure available on demand
 Reduction in overall exhaust emission
• Higher injection pressure and finer atomization of
 Reduction in particulate emission
fuel.
 Reduction in noise level
• Injection pressure created independent of Engine
 Improved fuel efficiency Speed
 Higher performance
Intake Side – General Arrangement
Wiring Harness
Coolant & Air Intake Manifold Arrangement
Thermostat Housing &

Cover
Alternator
Belt Tensioner
Starter
ECU
Poly V Belt Drive Arrangement
High Pressure Pipes
Fuel Supply Pipes
Coolant Pump & Suction Pipe
Damper
Hp Pump, Rail &
Injectors
Timing Gear Casing & Cover

D0836LFL08 D0836LFL13 (2VCR)
(Fan not shown for visibility of parts behind)
(VP44)
Exhaust Side - General Arrangement
Injector Overflow Pipe
Deareation Pipe
Flywheel Hsg & Flywheel

Air Compressor
D0836LFL08 D0836LFL13
(VP44) (2VCR)
MAN CATS II
Features:
1) User friendly
2) Engine health check up
3) Quick (matter of minutes as compared hours in case of
existing engines)
4) Accurate (no manual intervention)
5) Sensors signal analysis (monitoring)
Various tests which can be carried out on

1) OBD (On Board Diagnostics) D0836LFL13 engine without dismantling
interface parts unlike existing engines
2) Diagnostic memory (Read / evaluate 1) High Pressure test
/ erase of faults in simpler steps)
2) Compression test
3) Results in Suspect Parameter No.
(SPN) codes 3) Revolution up test
4) Printable results 4) Operating data
5) Injection volume @ respective speeds
6) Cranking data
Poly V Belt Drive
(MAKE: DAYCO)
Advantages:
• Use of single wider belt instead of

multiple thin belts, the belt may be put
under increased load without stretching.
Poly V belt
• Higher and uniform tension reduces slip,
which increases belt life. Belt Runs
cooler.
• Reduced slip can allow the use of lower

Poly V belt
ratio pulleys, this reduces the load on
engine, and increasing fuel economy and
V groove belt set for
existing engines available power.
• Easier to maintain and replace
Front Drive Arrangement
Advantages:
• The isolated drive for auxiliary i.e.

alternator & coolant pump.
• Drive is isolated from crankshaft

(torsional vibrations), improves bearing
life.
Automatic Belt Tensioner
(MAKE: DAYCO)
Advantages:
• No need of belt tension setting/adjustment over lifetime of

belt.
• Maintain uniform tension over life which reduces slip, and

increases belt life. Belt runs cooler and less noise
• Only one movable belt tensioner is required and all of the

peripheral components (Alternator, Air compressor, water
pump) can be simply be mounted to engine without the need
to swivel
Fuel Service Module
(MAKE: HENGST)
Advantages:
• Environment friendly
• The only serviceable part is filter element made up of cellulose

and recycled PA (Poly amide) material
• Easy to service as faster and cleaner filter change from top.
• Replaceable Cartridge
• Feasibility of mounting Fuel Heater, Pressure Sensor (optional)
• Hand pump and pre-filter adapted to filter housing
Existing Spin-on filter
Auxiliary: Air Compressor
Advantages:
• Minimal Oil carry over
• Improved life of brake system

components due to reduced oil carry
over and Low Break Air Temperature
230 cc 238 cc * * Currently 2VCR is with 238 cc AC and

(VP44) (2VCR)
by Dec 2013 we will shift to 318 cc
Advantages Over VP 44 Engine
• Improved fuel efficiency – 1-2 % • Faster and simpler engine diagnostics

• Reduced vehicle downtime and with MAN Cats-II
reduced maintenance due to faster • Accurate and faster monitoring of
and simpler engine diagnostics with engine health and sensors functioning
MAN Cats-II
• Quick coupling connectors used on
• Latest technology - Highly Durable & fuel lines ensures pressure tightness,
reliable faster removal and fitments.
• Single wider Poly V Belt increases
belt life and reduces slippage and
load on engine.
LOWER OPERTAING BETTER

COST SERVICEABILITY
USER & ENVIRONMENT

IMPROVED DURABILITY
FRIENDLY
• Improved life of engine due to better • Reduction in overall exhaust emission

lubrication • Reduction in particulate emission
• Reduction in noise level
Warranty & Service
 Warranty and Service intervals will remain same in 2 VCR Engine as that of
previous VP44 Engine
Warranty
Long Haul Vehicles Tippers & Concrete Mixers
24 Months / Unlimited kms. 18 Months / 3000 Hrs.
Oil Change Intervals

Engine Oil 40000 kms/150 days 900 hrs/60 days
Gear Oil 60000 kms/240 days 1800 hrs/120 days
Rear Axle Oil 60000 kms/240 days 1800 hrs/120 days
Steering Oil 100000 kms/ 1 yr 3600 hrs/1 yr
Coolant 100000 kms/ 1 yr 3600 hrs/1 yr
Free Services
1 20000 kms/75 days 450 hrs/30 days
2 40000 kms/150 days 900 hrs/60days
3 60000 kms/225 days 1350 hrs/90 days
4 80000 kms/ 300 days 1800 hrs/120 days
5 100000 kms/ 375 days 2250 hrs/150 days
6 120000 kms / 450 days 2700 hrs/180 days
Pricing and Models
 All 280 HP models will be slowly replaced by 280 HP 2VCR engines over period of next 2-3
months
 CLA 25.280 & 31.280 Tippers, CLA 49.280 Tractor Heads and Special application chassis will
be made available with 2 VCR engines
 Even though there is cost impact to the tune of Rs.30,000 to 40,000/- per vehicle , we are not
increasing any price for 2VCR engine models till Sept 2013.
 This inline with the recent commitment of Top Management that the prices will not be revised till
Sept 2013.
For further details please contact
Mr. Abhijeet Malwadkar Mr. Pravin Matey
Mr. Raju Ghandas
Thank You
MAN [Company] [optional: Brand] Author Current topic 00.00.2012 < 17 >

2 VCR Presentation Product MGMT - May 2013 - V1

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Two Valve Common Rail (2VCR) Engine

SN. Parameters 2 VCR (New Engine) VP44 (Existing Engine)

2 Engine Type 6cylinder , Inline ,Vertical 6cylinder , Inline ,Vertical

4 Valve per Cylinder 2 2

Electronic Diesel Control ;

Thermostat Housing &

Timing Gear Casing & Cover

Flywheel Hsg & Flywheel

Various tests which can be carried out on

• Use of single wider belt instead of

• Reduced slip can allow the use of lower

• Easier to maintain and replace

• The isolated drive for auxiliary i.e.

• Drive is isolated from crankshaft

• No need of belt tension setting/adjustment over lifetime of

• Maintain uniform tension over life which reduces slip, and

• Only one movable belt tensioner is required and all of the

• The only serviceable part is filter element made up of cellulose

• Easy to service as faster and cleaner filter change from top.

• Feasibility of mounting Fuel Heater, Pressure Sensor (optional)

• Hand pump and pre-filter adapted to filter housing

Existing Spin-on filter

• Minimal Oil carry over

• Improved life of brake system

230 cc 238 cc * * Currently 2VCR is with 238 cc AC and

• Improved fuel efficiency – 1-2 % • Faster and simpler engine diagnostics

LOWER OPERTAING BETTER

USER & ENVIRONMENT

• Improved life of engine due to better • Reduction in overall exhaust emission

Oil Change Intervals

Mr. Abhijeet Malwadkar Mr. Pravin Matey

Mr. Raju Ghandas

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