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EPA Tier 4 Information

25 – 74 Horsepower Diesel Powered Turf Equipment Emissions Regulations

The Environmental Protection Agency’s Tier 4 diesel engine emission reduction mandate may have already had an impact on your business. The good news is that all Tier 4 compliant turf equipment manufactured going forward will be better for the environment and healthier for everyone.

 

Diesel Particulate Filter Parked Regeneration Instructions

Understanding the function of diesel particulate filter (DPF) and the regeneration process are important aspects of owning Toro Tier 4 Diesel machines. When an exhaust DPF (soot filter) becomes restricted, it must be addressed immediately. Below are instructions on how to perform a regen using the different InfoCenter™ controls

Tier 4 DPF Regeneration Brochure - English       Tier 4 DPF Regeneration Brochure - Spanish

 

3-Button InfoCenter™ Instructions

Original Software Instructions (2013-2017)       New Generation Software Instructions (2018-Present)

 

5-Button InfoCenter™ Instructions

Original Software Instructions (2013-2017)       New Generation Software Instructions (2018-Present)

 

What is EPA Tier 4?
The EPA Tier 4 Standard is About Cleaner Air!

All US regulated emission standards, including Tier 4, are extensions of the “Clean Air Act” (1963) which was enacted to reduce air pollution. The Environmental Protection Agency (EPA), which is the Federal organization responsible for managing and regulating the Clean Air Act, put forth a multi-year plan in the mid 1990’s with “tiered” mandates to reduce the level of harmful emissions such as particulate matter (PM) and Nitrogen Oxides (NOx) that enter the air via diesel engine exhaust. The "final" and most technologically challenging implementation stage, whereby engine and turf equipment manufacturers are required to produce products that comply with these most stringent emission reductions, is called “Tier 4”. The Tier 4 emission standard will reduce already reduced emissions of PM by 90%. To give you a sense for how stringent the Tier 4 standard is, consider the fact that in many parts of the United States, the air leaving Tier 4 compliant machines will actually be cleaner than the incoming air! The EPA Tier 4 specification was first applied to industries with large on-road vehicles (such as Semi Trailers and other diesel powered Trucks) and followed shortly thereafter by large off-road equipment categories (such as Agricultural and Construction Equipment). In each case, vehicles or equipment with diesel engines greater than 75 horsepower (hp) were required to comply by specified dates. In the Turf Industry, most of the commercially available diesel powered products are in the 25 to 74 hp range and the Tier 4 mandate requires compliance for any products produced in this horsepower/performance category.

What EPA Tier 4 Means to​ Manufacturers. Compliance is Mandatory.

Compliance with EPA Tier 4, or any other Federal/State regulatory requirements, is not optional. All manufacturers must comply if they wish to continue to sell diesel powered products in this horsepower/performance range.

While Tier 4 may seem "new" to many in our business, The Toro Company has been working with our engine suppliers over the past decade to successfully comply with each Tier of the emission regulations. Since the compliant engines to meet progressively higher emission standards were more easily interchangeable in the past, much of the burden to implement the required changes fell on engine manufacturers. Going forward, however, the incorporation of new Tier 4 compliant diesel engines into turf equipment requires significant equipment redesign because the level of emission reductions mandated in this stage will require more sophisticated fuel injection/combustion systems and exhaust after treatment systems.

Exhaust After-treatment for EPA Tier 4 Solutions

Tier 4

  • In addition to more sophisticated engine electronics, the exhaust after-treatment is key to achieving EPA Tier 4 compliance. Key elements of the exhaust after-treatment systems include Diesel Oxidation Catalysts (DOCs) and Diesel Particulate Filters (DPFs).
  • The process of removing particulate matter and NOx from the exhaust starts when the exhaust reacts with a special catalyst to transform a portion of the particulate matter into harmless substances such as water and carbon dioxide.
  • The after-treatment process then pushes the remaining particulate matter into a Diesel Particulate Filter. This filter uses a special ceramic wall flow filtration process that further separates particles from the exhaust.
  • Finally, the particulate material that is collected in the DPF is cleaned and purged via a high temperature regeneration process. The "burn-off" of material during this process helps maintain the efficiency and efficacy of the filtering process. This is called DPF Regeneration.

Each of the new diesel engine/exhaust systems:

  1. require more sophisticated electronics [to monitor and control emissions]
  2. are physically larger in size, and
  3. have new and more expensive components [particularly in the exhaust after treatment area]

Significant redesigns were required to integrate the above Tier 4 compliant diesel engine changes with existing equipment/models. Examples include: retooled engine compartment housings, modifications to chassis frames, and re-engineered cooling systems to manage higher temperature exhaust, to name a few. In many cases over a third of the parts for a given model had to be reworked, replaced or otherwise re-engineered! Because of this, existing models were simply not "retrofit" capable. Toro, alone, produces over twenty diesel powered models in the 25 to 74 horsepower range that had to be addressed.

The obvious message, which no manufacturer wants to convey, is that the design, manufacturing and component costs – to deliver Tier 4 compliant diesel powered product has increased significantly on machines manufactured in 2013. Cost reductions, while always a high priority in product redesigns, are not sufficient to offset cost increases.

Strategic Appproaches to EPA Tier 4 Compliance

End users in other industries that have already lived through the transition to Tier 4 have taken a few different strategic approaches when developing their capital spending plans for related equipment:

  • Go "Green" - Some end-user companies embraced the new Tier 4 product and wanted to position themselves as leaders in the "green"space. They got in line for the new products early, despite the higher prices, to lead the charge toward cleaner air.
  • Business as Usual - Other companies chose to simply pay the market price (even if it was forecasted to go up substantially) when their current captial plan called for new equipment or when their equipment simply reached the end of its useful life.
  • Buy Used - Equipment manufactured prior to 2013 is "grandfathered-in" and does not need to be retrofitted to Tier 4 standards.
  • Pre-Buy - Many companies decided to buy equipment in advance of the mandatory Tier 4 changeover (at lower prices) to defer the need for higher priced products as long as possible and to give them more time to adjust to the new market pricing.

Even though some Tier 4i models are still available, eventually, the only option for customers purchasing diesel powered product in the 25 to 74 hp range will be to buy a Tier 4 compliant product. Therefore, the purpose of learning about this issue now is so that all customers can develop and implement an acquisition strategy that meets their specific needs.

As you review your own needs and options for capital spending on turf equipment, you may also want to consider researching how other end-user customers in other industries dealt with Tier 4 compliance.

  • Other industries experienced significant pre-buy behaviors.
  • Increased pre-buy demand created availability issues for lower priced equipment.
    • Equipment manufacturers were unable to meet the unforecasted demand.
    • Engine manufactures capacity became constrained as they converted existing manufacturing lines to the new Tier 4 product.

The past is not always a good predictor of the future. However, we encourage customers to plan early, so they can evaluate multiple options to maximize their ROI.

What can or should you do?

Act now to learn more and share what you know!

  • Become knowledgeable about the EPA’s Tier 4 standards.
  • Educate your leadership team and financial stakeholders about Tier 4 and the impact it will have on your equipment purchasing plans.
  • Understand the availability for both existing and new Tier 4 technology solutions and how it may influence your options and decisions starting in 2013.

Additional Resources Where You Can Learn More.

Conduct simple internet search on EPA Tier 4 Emission Standards. There is plenty of material to help get you grounded in EPA Tier 4. The following links should help get you started:

Toro Literature:
EPA Tier 4 Brochure

Related Links

The Diesel Forum
www.dieselforum.org

General info on off-road diesel engines, equipment, retrofitting, etc.
www.clean-diesel.org

Association of Equipment Manufacturers
www.aem.org/SRT/Regulatory/Tier4/

Bobcat Website - Tier 4 Content
www.bobcat.com/excavators/tier4

Catepillar websites
www.cat.com/technology/acert-technology

Cummins Website
www.tier4.info

FAQs

Tier 4 refers to a specifically defined level of federally mandated air-quality emissions standards established by the U.S. Environmental Protection Agency (EPA) that apply to new diesel engines used in off-road equipment. Essentially, the Tier 4 standard requires engine manufacturers to reduce the levels of particulate matter and oxides of nitrogen (NOx) to a level that is 50-96 percent lower than existing diesel engines. Any company that integrates engines into other off-road equipment solutions (e.g. large area rotary and reel mowers) must also integrate new Tier 4 compliant engine technologies into their products.

In the mid 1990’s, the EPA outlined a “tiered” series of emissions regulations governing new off-road engines and equipment – culminating at Tier 4. These standards establish progressively lower allowable emissions of nitrogen oxides and particulate matter. It is a complex system and compliance dates are based on the size of engine (in hp and /kW-hr) and other factors. On the road to clean air, you might think of “Tier “0” as the starting line - where the diesel engine has basically no modern emission controls whatsoever, and Tier 4 as the finish line - where the diesel engine performing the same job will nearly eliminate particulate matter and nitrogen oxide emissions from the exhaust.

The general answer is that any diesel powered product with 25 horsepower and larger engines will be impacted in some way. Nearly all of these products are in our Reelmaster and Groundsmaster Product Lines. A list of each model that meets the above criteria is shown below.

Groundsmaster Rotary Mower Models

  • GM 3500 (33HP)
  • GM 3505 (33HP)
  • GM 7210 (33HP)
  • GM 4300 (44HP)
  • GM 360-2 WD (36HP)
  • GM 360-4 WD (36HP)
  • GM 360-4 WD w/cab (36HP)
  • GM 4000 (56HP)
  • GM 4010 (56 HP)
  • GM 4100 (56HP)
  • GM 4110 (56 HP)
  • GM 4500 (56HP)
  • GM 4700 (56HP)
  • GM 5900 (99HP)
  • GM 5910 (99HP)

Reelmaster Reel Mower Models

  • RM 5410 (36HP)
  • RM 5510 (36HP)
  • RM 5610 (44HP)
  • RM 7000 (49HP)

Multi Pro Model

  • MP 5800 (36HP)

Manufacturers, like Toro, have partnered with Engine Manufacturers to develop Tier 4 compliant solutions for the Turf Industry. Due to significant redesigns and reengineering, all manufacturers’ prices will increase roughly 15%. Research in other industries that have been required to introduce Tier 4 compliant solutions in the past (such as Semi-Trailer Trucks, Agricultural and Construction Equipment, Compact Loaders, etc.) shows that it was not uncommon for prices to increase by 10% to 18%.

Environmentally, the new Tier 4 engines will be cleaner for the environment. Economically these new machines will have significantly higher acquisition costs. In short, a Tier 4 purchase is better for the environment and better for the long-term health of our communities. If you want to continue to use diesel powered equipment and be “green”, then Tier 4 machines are right for you. The disadvantage is that the cost of Tier 4 compliant equipment is much higher than Tier 3 or below.

Yes. New Tier 4 generation engines and equipment are required the use of ultra-low sulfur diesel fuel(ULSD) which has no more than 15 parts per million (ppm) sulfur. ULSD fuel has been used since 2006 in on-highway vehicles and is now widely available. (For more information on clean diesel fuel requirements visit www.clean-diesel.org)

Tier 4 engines using a diesel particulate filter (DPF) do need to be removed and reconditioned (cleaned) at an authorized service center at approximately 3000 to 5000 hours. No other special maintenance is required. Normal maintenance intervals for oil and filter changes may be extended compared to today’s engines.

According to federal law and EPA regulations, manufacturers are encouraged to produce Tier 4 compliant only solutions for U.S. customers now that the Tier 4 regulation is in effect. The law does include some flexibility to ease the transition, but eventually – all Turf Equipment with Diesel powered engines of 25 horsepower and above must comply!

With that said, equipment distributors can continue to sell inventories of equipment from the previous generation technology (Tier 3) until the inventory is depleted.

Each Turf Equipment manufacturer may have different technology and unique transition plans, so it will be important for you to understand these requirements and ask your distributor about their specific plans.

Machines slated for export outside the U.S. are not required to meet EPA mandated emission standards (i.e. Tier 4). Manufacturers, therefore, have the ability to continue selling existing models or to offer alternative solutions in countries not under EPA jurisdiction. With that said, other Countries such as Canada and Japan are enacting similar legislation that will require Tier 4 equivalent products be sold in their countries.

Existing equipment that you own is “grandfathered in” and does not need to be replaced until the normal end-of-life cycle. The Tier 4 requirements apply only to NEW engines — including those sold in California and all other states. There is no federal requirement to upgrade any existing engine to the new Tier 4 standards. California is pursuing separate state law requirements for the modernizing and upgrading of off-road machines and equipment in that state. (For more information see www.arb.ca.gov/diesel).

Products with engines rated below 25 horsepower are already Tier 4 compliant.

Yes. Biodiesel is registered as a fuel and fuel additive with the Environmental Protection Agency (EPA) and meets clean diesel standards established by the California Air Resources Board (CARB). Neat (100 percent) biodiesel has been designated as an alternative fuel by the Department of Energy (DOE) and the US Department of Transportation (DOT).

Biodiesel blends alter combustion and exhaust temperatures and may impact the performance or durability of some new emissions control technologies when used in a Tier 4 engine. Equipment owners are advised to check carefully with their OEMs regarding permitted fuels or fuel blends and their use in Tier 4 equipment.

No, due to the necessity for complex retooling and multiple modifications, we do not offer a solution to “retrofit” a current product to a compliant Tier 4 product.

The new Tier 4 Compliant solutions have:

  1. all new engine and exhaust systems
  2. more sophisticated electronic controls
  3. additional – after-treatment for removal of NOx and Particulate Matter
  4. redesigned frames and engine compartments to accommodate physically larger engine/exhaust system modules
  5. updated cooling systems.

The areas above represent the major areas where changes are required to meet the Tier 4 emission reduction mandate, but it is by no means an exhaustive list.