Fresh Air Fuels Fresh Design

Years from now, farm equipment historians will likely write about the tightening diesel emissions regulations as an epoch, an event that helped usher in a new era of off-highway machine design and technology.

As Tier 4 Interim deadlines arrive (and final regulations loom in the not-too-distant future) equipment dealers and buyers are being introduced to brand-new machines in nearly every segment of the off-highway industry. In many cases, redesigns are required in order to make room for the new emissions-fighting components. It’s also an opportunity to make upgrades in non-related areas, such as styling and operator comfort.

“Several years ago, we began discussing how we were going to adapt all of the changes that would be required to meet emissions regulations into our sprayers,” says Chad Ringer, lead engineer for Equipment Technologies (ET), Mooresville, IN.

This summer and fall, dealers and farmers were introduced to the results of that research, which have influenced all three models of ET’s Apache mechanical-drive sprayers. “The 2011 model year sprayer represents the culmination of years of customer feedback and planning,” says Paul Nielsen, national sales manager, ET. “It is truly rewarding to see all these changes come together without compromising what makes the Apache special — the promise of efficiency and ROI. Our customer, the farmer who considers himself a businessman, appreciates that.”

A reason for change

While the styling for the AS720, AS1020 and AS1220 model sprayers is a significant departure from the previous series, Ringer says that the emissions requirements “molded the changes, but did not dictate them.”

Because the previous sprayer series was introduced in 2005 and has been little changed since (at least to passersby), the team at ET felt it was time to make styling changes while enhancing the functionality of the machine.

In so doing, they sought ways to give more value to the customer. The operator’s “office”, the cab received a significant amount of attention. The three Apache models share the same cab, which is unique to ET. The cab is 12% larger and fulcrum-mounted at four points (up from three in previous models). The additional support and wider stance reduces — by more than 37% — the jarring forces that had previously been transmitted to the operator. Wrap-around glass gives the operator a better view of the front wheels and the booms. Interior noise has also been reduced: By moving noise sources such as the engine farther from the operator, ET reduced in-cab noise by 9%.

A rear-hinged door and larger catwalk make entering the cab simpler and safer, while a steering column featuring HVAC adjusters helps the operator get comfortable with ease.

A custom, roto-molded tank is contoured to the chassis and no longer utilizes a tank skid. This allows the tank to be lowered and contributes to better visibility of the booms, a lower center of gravity and a better ride.

One of the most significant necessary changes to the machine’s design was widening the chassis to make way for the cooling capacity required by the new engines.

“In terms of challenges directly caused by Tier 4 Interim engine requirements,” says Ringer, “we had to design for a 45% increase in required heat rejection, which meant we needed a larger cooling system.” The Apache’s frame was widened to facilitate that, and the right side of the engine was given more room for new exhaust aftertreatment devices.

Tier 4 Interim emissions regulations take effect January 1, 2011 for engines over 173 hp. Particulate matter will be reduced by 90% and oxides of nitrogen (NOx) by almost 50%. Beginning January 1, 2012, the Tier 4 Interim regulations will take effect for the 75-173 hp range.

ET uses Cummins’ QSB engine, rated for 163 hp (AS720), 173 hp (AS1020) and 215 hp (AS1220). Like many OEMs, ET’s strategy for compliance is to take advantage of government certificates that will allow it to use Tier 3 engines for a period of time. Certificates will be used for the Apache 720 and 1220, while the 1020 sprayer, which makes up nearly 50% of the company’s overall sales, will be transitioned to Cummins Tier 4 Interim QSB engine.