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Adam Gryglak, Lead Diesel Engineer Ed Waszczenko, Engine Durability Engineer Scott DeRaad, NVH Engineer
LEADERSHIP F-Series: Best selling truck in U.S. for 32 years; in Canada for 43 years 33 million sold in 60 years Largest customer base: 9 million strong More trucks on road with 250,000 miles
SUPER DUTY CUSTOMER ,[object Object]
 They build America’s infrastructure
 Wyoming energy company tows 21,000 lbs  to    natural gas wells  ,[object Object],   buggies” and goes off-road ,[object Object],   of pounds concrete        ,[object Object],  tow trucks, aerial trucks
DIESEL TECHNOLOGY Designed and built by Ford New compacted graphite iron block v. cast iron  Aluminum cylinder heads v.     cast iron Innovative inboard exhaust and outboard intake architecture Industry-first single-sequential turbo housed in the “V” of the engine block 30,000 psi high-pressure fuel system Compatible with B20 Biodiesel Tested to 250,000 miles  111 powertrain patents
TWICE THE STRENGTH,  MINUS THE WEIGHT Compacted graphite iron block contributes to 160-pound lighter total engine
INBOARD EXHAUST Outboard Exhaust vs. Inboard Exhaust Smarter Design. Greater Efficiency.  Better Performance.
SINGLE SEQUENTIAL TURBO One impeller, two wheels More responsive Seamless transition Two turbos. One package.
30,000 PSI HIGH PRESSURE  FUEL SYSTEM Common-rail System Rigorous testing. Proven durability.
ALUMINUM CYLINDER HEADS Reduced weight Six head bolts Dual water jackets
NOISE VIBRATION HARSHNESS Keeping it Quiet Twin pilot combustion Robust turbo mount  Tuned acoustic covers Composite oil pan Inboard exhaust –   less radiated noise
EASY TO WORK ON Cab-on service capability  External fuel injectors, lines, glow plugs Spin-on oil filter Repair time reduced by: Turbo – 4.5 hours EGR cooler – 5.2 hours  High pressure fuel pump – 4.7 hours  DEF refill timed to oil     change interval  Less Down Time  + Greater Productivity    Better Bottom Line
TESTED FORD TOUGH ,[object Object],   hardware tooling ,[object Object],    - Previous warranty data      - Customer data to develop real-world       test programs: driving styles, road        types, vehicle usage ,[object Object]
 Thousands of hours in over-boosted,    over-pressurized, overloaded conditions ,[object Object]
 Started engine below zero 2,600 times

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Diesel Forum Presentation

  • 1. Adam Gryglak, Lead Diesel Engineer Ed Waszczenko, Engine Durability Engineer Scott DeRaad, NVH Engineer
  • 2. LEADERSHIP F-Series: Best selling truck in U.S. for 32 years; in Canada for 43 years 33 million sold in 60 years Largest customer base: 9 million strong More trucks on road with 250,000 miles
  • 3.
  • 4. They build America’s infrastructure
  • 5.
  • 6. DIESEL TECHNOLOGY Designed and built by Ford New compacted graphite iron block v. cast iron Aluminum cylinder heads v. cast iron Innovative inboard exhaust and outboard intake architecture Industry-first single-sequential turbo housed in the “V” of the engine block 30,000 psi high-pressure fuel system Compatible with B20 Biodiesel Tested to 250,000 miles 111 powertrain patents
  • 7. TWICE THE STRENGTH, MINUS THE WEIGHT Compacted graphite iron block contributes to 160-pound lighter total engine
  • 8. INBOARD EXHAUST Outboard Exhaust vs. Inboard Exhaust Smarter Design. Greater Efficiency. Better Performance.
  • 9. SINGLE SEQUENTIAL TURBO One impeller, two wheels More responsive Seamless transition Two turbos. One package.
  • 10. 30,000 PSI HIGH PRESSURE FUEL SYSTEM Common-rail System Rigorous testing. Proven durability.
  • 11. ALUMINUM CYLINDER HEADS Reduced weight Six head bolts Dual water jackets
  • 12. NOISE VIBRATION HARSHNESS Keeping it Quiet Twin pilot combustion Robust turbo mount Tuned acoustic covers Composite oil pan Inboard exhaust – less radiated noise
  • 13. EASY TO WORK ON Cab-on service capability External fuel injectors, lines, glow plugs Spin-on oil filter Repair time reduced by: Turbo – 4.5 hours EGR cooler – 5.2 hours High pressure fuel pump – 4.7 hours DEF refill timed to oil change interval Less Down Time + Greater Productivity Better Bottom Line
  • 14.
  • 15.
  • 16. Started engine below zero 2,600 times
  • 17.
  • 18.
  • 19. Clean room manufacturing environment
  • 20.
  • 22. Data-driven Quality Operating Systems
  • 23. In-plant dynamometer test stations
  • 24. Prototype builds exceeded quality metrics