Cummins Spark Ignited EnginesISL9-GISX12-G

What is Natural Gas?BenefitsModels ISL9-G, ISX12-GMaintenance

•Oil•Fuel

PaybackSummary

AGENDA

What is Natural Gas ? Formed from slowly decomposing buried remains of

plant and ocean life from over 200M years ago. Concentrated in layers of rock, brought to the surface

via well heads. Simple Chemical make-up of ONE carbon and four

hydrogen atoms – that’s what makes it burn so clean. CH4, Natural Gas, currently

meets 1/4th the energy needs, and will grow by 50% over the next 20-years. Since the 1960s, CNG has

become a vehicle fuel alternative to oil-based gasoline and diesel fuel.

Natural Gas—A Safer Fuel !Lighter than air, rises and doesn't

accumulate in low places Ignites at temperatures of approx. 600 CRich mixture burns off slowlyNon-toxicOdorless: a detection fragrance is addedEvaporates quicklyDOES NOT FREEZE !

Benefits• Natural Gas costs 30-50% less

than diesel• Return on investment and fuel

savingsEconomics

• Domestic production and supply• Reduces crude oil importsEnergy Policy

• Reduces greenhouse gas emissions

• Lower engine noise• Simple aftertreatment

Environment

Stoichiometric stoi·chi·o·met·ric [stoi-kee-uh-me-trik] –adjectiveChemistry. 1. of or pertaining to stoichiometry. 2. pertaining to or involving substances that are in

the exact proportions required for a given reaction. Stoichiometric is the ideal combustion process

during which a fuel is burned completely. A complete combustion is a process which burns all the carbon (C) to (CO2), all hydrogen (H) to (H2O) and all sulfur (S) to (SO2). The stoichiometric ratio is the perfect ideal fuel-air

ratio where the chemical mixing proportion is correct. When burned all fuel and air is consumed without any excess left over.

ISLG Integrated Fuel Housing

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EGR

EGR

Fuel Flow Valve 3933841

Gas Mass Flow Sensor 3929159

Fuel Outlet Press Sensor 4921479

Fuel Inlet Press Sensor 4921495

NG Fuel flow path

Fuel Reg 3970615

FSOV 3931710

Throttle Act. 4934537

Maintenance-Free Aftertreatment Three-Way Catalyst, Passive Device Easy Install packaged as a muffler - vertical or horizontal mount

Weighs approx. 100 pounds Minimizes vehicle impact and Maintenance No DPF/regeneration NOR SCR/DEF Fluid required.

ISL9-G Technical Specifications

Introducing the ISX12-G

Available for Order Q1 2013

Maintenance Intervals – Same as Diesel

Eg: Truck application Hours Miles Kilometers Months

Check CAC cooler, piping and Air Cleaner 250 7500 12,000 3

Oil & Filter* 500 15,000 24,000 6

Coolant Filter** None¹ None¹ None¹ None¹

Spin-on Fuel Filter 1,000 30,000 48,000 12

Spark Plugs 1,500 45,000 72,000 18

Standard Coolant 2,000 60,000 96,000 24

Overhead Adjustment*** 2,000 60,000 96,000 24

Air Cleaner/Element Follow vehicle manufacturers published recommendations

Default interval is the hours stated. Interval is whichever comes first – hours, miles or time.Refer to Owners Manual for complete details on Maintenance Intervals.

¹ If engine is equipped with an optional coolant filter, it will need to be replaced at the same intervals as the oil filter. Regardless if the engine is or is not equipped with a coolant filter, SCA/DCA additive levels must be checked according to the interval listed in the Owners Manual.

*Assuming normal duty cycle/based on 30 mph average speed.**Do not change if SCA above 3***Initial Overhead Adjustment at 1,000 hours

Engine Maintenance Specific to Natural Gas Spark Plug Replace – 1,500 hours

•Inspect & Test Ignition Coil – 1,500 hoursInitial Overhead Valve Set – 1,000 hours

•Every Overhead Valve Set – 2,000 hoursDrain Fuel/Water Separator DAILYUse only natural gas engine oil

• (CES 200074)

Use 15W-40 Natural Gas Engine OilCummins Westport natural gas engines require SAE 15W-40natural gas engine oil that is available from major oil suppliers – Careful attention must be paid to

engine oil specifications – CES 200074 Low Ash– Natural gas engine oil has different

properties than diesel engine oil– Higher ash oils (>0.6 percent

sulfated ash) can cause valve and/or piston damage and lead to excessive oil consumption and degradation of the catalyst

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Do not use diesel engine oil in a natural gas engine. If diesel engine oil is used, valve torching, piston

scuffing, and reduction in spark plug life will occur.

Maintenance Tools 3375044 Torque wrench 3375049 Oil filter wrench 3376592 Torque wrench (valve adjustment) 3376807 Engine coolant and fuel filter wrench 3822524 Belt tension gauge, click type (v-belts and v-ribbed with 4 or 5 ribs)

3822525 Belt tension gauge, click type (v-ribbed with 6 to 12 ribs) ST-1138 Belt tension gauge (v-ribbed belts, 6 to 9 ribs) 3163196 Torque wrench adapter ST-1273 Pressure gauge 0 to 1900 Hg [0 to 75 in Hg] 3824510 Electronic contact cleaner 3163099 In-line data link adapter kit QuickServe™ Online Cummins® INSITE™ electronic service tool software

Maintenance Tools continued

3164486 Tester, Ignition 3825137 Kit, NG engine tool, includes:

– 3376589 Female Compucheck™ quick connect– 3823983 Compression gauge/adapter set– 3823984 Combustible gas detector– 3824876 Plug socket– 3824645 Pressure vacuum module– 3824648 Automotive meter (Flukemeter)

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OEM Supplied Fuel System Components(CNG)Mounted on the vehicle chassis.Regulates storage pressure down to engine specification

pressure (70-150 psi).Note drain on Fuel Filter has a drain requirement.

•Must be drained if there is 1 oz of liquid.•Make sure to have mounted in accessible location.

Incorporate Engine Heaters: Oil Pan heaters & Block heaters

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Fuel Natural Gas fuel for the ISL G can be stored on the vehicle in either

liquid (LNG) or compressed (CNG) form. Natural gas fuel must meet ISL G fuel specs per AEB 79.05 Minimum Methane Number (MN) is 75 Cummins Westport approves the use of up to 100% biomethane

that meets Cummins published natural gas fuel specifications ISL G requires fuel to be regulated to max 150 psi, min 70 psi

or

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CNG Range

Natural gas engine mpg lower than diesel– Lower compression– Throttled inlet versus fuel injected

Example:– Diesel fuel economy 5 mpg– Natural gas fuel economy 4.5 mpg

Diesel Fuel Storage 60 g = range 300 miles

CNG Fuel Storage 60 dge = range 270 miles

Important to look at cost per mile as natural gas fuel cost is less than diesel.

Specing for The Right Applications ISL-G

– Medium Duty Market– Refuse / Dump / Mixer– Transit and School Bus– Pickup and Delivery Truck– Medium Duty Specialty Vehicles

(street sweeper, yard spotter, etc…) – Less then 54,000 LB CGWR

ISX12-G– Regional Haul Truck– Regional Tractor/trailer– Vocational: Refuse / Dump / Mixer– 65,000 LB CGWR; Diminishing load 80,000 LB

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Value Spec Tool – Payback Calculator

Additional NG Scheduled Maintenance Cost

~$1,135/year$0.01.1 per mile

(Spark Plugs and Overhead Valves)

CommentsNatural gas (NG) trucks cost more

NG Fuel cost is $25,337/yr lower

No DEF required with NG

NG maintenance higher ($1,135 per year)

Save $21,090.97 per year, per truck

1.9 year Payback on Incremental Truck cost

Training: Key to Success for New NG Users There are operation & maintenance differences

between a NG and diesel vehicle. New users need an orientation for proper O&M:

– Follow Cummins maintenance guidelines– Use only approved Cummins parts – Use proper fuels and lubes

Training can be found in the typical sources:– Cummins Virtual College ISL-G DVD Training Library– Quick Serve On Line– CumminsWestport.com– ngvi.com, Natural Gas Vehicle Institute

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Cummins Westport Website

25www.cumminswestport.com

■ New Website launched May 15, 2012■ Great source of information about

natural gas engines and vehicles.■ Features the Natural Gas Academy,

a series of instructional videos■ Designed to provide a general

overview of natural gas as a fuel whether it is compressed (CNG) or liquefied (LNG), and how it is used with vehicles.

What did we learn?Natural Gas is Safe to handle and manage.Simpler solution - No Aftertreatment.Easy Maintenance.DRAIN FUEL FILTER DAILY !

Diesel-like responsiveness

Half the Fuel Costs

Broadening product-line for all applications.All supported by the World Class Cummins

Dealer Network.Natural Gas is OUR fuel of the future!

Thank Youfor the Invitation

to join You today!

APPENDIX

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Up to 20% Lower Greenhouse Gas Emissions

Source: Presentation to AFVI convention by Don O’Conner (S&T)2 Consultants May 2008

As natural gas fuel economy improves, CO2 emissions are reduced

CH4 emissions, adjusted to consider GHG impact are less than 10% of total GHG emissions.

Well to Wheel analysis with GHGenius modeling tool predicts up to 20% WTW GHG emissions for natural gas vs. diesel.

Using landfill gas or anaerobic gas as a biomethane fuel increases GHG difference to ~90%.

Cummins Westport approves the use of biomethane that meets fuel specifications.

Natural Gas Shop Upgrades As a reference the National Fire Protection Agency

publishes an industry standard (NFPA 30A) for NGV facilities.– Also have guidelines for installation and inspection of NG fuel

systems on vehicles (NFPA 52)– Both are available at the website - NFPA.org

Local building codes and regulations vary by location– Consult with industry experts and local officials

Cummins Westport Confidential Dec 2011

Natural Gas Shop Upgrades

Highlights of Repair Facility Guidelines– Methane Gas Detection System

• Sounds an alarm, deactivates heating systems, and activates a mechanical ventilation system (i.e. opens bay doors and roof vents, fans etc)

– Air Handler System • Circulates air within the shop to prevent accumulation of methane

– Electrical Upgrades • All electrical relocated to be at least 18” below the ceiling

– Open Flame Heater Restrictions.

Cummins Westport Confidential Dec 2011

Natural Gas Shop Upgrades

Highlights of Repair Facility Guidelines– Methane Gas Detection System

• Sounds an alarm, deactivates heating systems, and activates a mechanical ventilation system (i.e. opens bay doors and roof vents, fans etc)

– Air Handler System • Opens doors and circulates/evacuates air within

the shop to prevent accumulation of methane

– Electrical Upgrades • All electrical relocated to be at least 18” below the

ceiling

– Open Flame Heater Restrictions.

Cummins Westport Confidential Dec 2011

Methane detection

Ceiling exhaust fan

Technician Training

Technicians need additional training and certification to repair natural gas fuel systems.– Community College– Natural Gas Vehicle Institute (www.ngvi.com)

Cummins Virtual College training and certification available for CWI natural gas engines.– Cummins Distributor

Vehicle manufacturers typically provide orientation training, but often do not require special certification for vehicle fuel systems.

Are there any special service requirements for natural gas vehicles?

Yes.– Dealer facilities may need to be modified to meet

building and/or fire codes.– Technicians need to be trained and certified on

natural gas components. • Fuel System• Engine

Natural Gas Engine Key Product Attributes

– 4 cycle, spark ignited, in-line 6 cylinder, turbocharged, CAC– Displacement – 11.9 litres (726.2 cu in)– Peak rating: 400 hp, 1450 lb-ft *– EPA/CARB certified at or below EPA10 emission levels– Dedicated natural gas engine

• Will operate on CNG or LNG• Capable of using up to 100% Biomethane

– Three Way Catalyst after-treatment– Engine braking– Manual/Automatic Transmission capable

• No AMT at launch

Schedule– Commercial launch: Early 2013– Currently in field tests

* Preliminary Rating Specification – Subject to Change

ISL G Product Features and Benefits 8.9L Stoichiometric Cooled EGR engine with

spark ignition

In production since mid-2007

Low emissions– 0.20 g/bhp-hr NOx– 0.01 g/bhp-hr PM

Three Way Catalyst Aftertreatment

Diesel like Performance, Reliability and Durability– Same rated speed– Similar torque curve– Over 30% more torque at idle vs. lean burn– Improved fuel economy of 5% vs. lean burn

Over 80% parts commonality with ISL9

Compatible with CNG, LNG, or Biomethane (RNG) Renewable Natural Gas

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What is the Same Between ISL9 & ISL G?

Major Engine Components & Technology– Block, crankshaft, main bearing, piston rods– Over 80% parts commonality– Cooled EGR

500 hour Maintenance Interval

Parts, Service, Training, Warranty– Cummins Distributor Network

320, 300, 280, 260 and 250 HP rating

Compatible w/ Cummins Diagnostic Tools– Insite– QuickServe Online

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What is Different Between ISL9 & ISL G?

Cylinder Head 2 Valve 4 Valve

Ignition Spark Ignition (spark plugs) Compression Ignition

Fuel System Intake Manifold Common Rail

Aftertreatment Three way catalyst Particulate Filter + SCR

Compression Ratio 12:1 16.6:1

Maintenance Cost

Cost of maintenance related to ignition and overhead valve adjustments adds incremental maintenance cost for the ISL G versus ISL9. This cost is typically more than offset by fuel cost savings with natural gas.

Lubricating Oil Natural gas engines require a specific oil that meets Cummins specification CES 20074

Noise Natural gas engines are up to 10db quieter at idle38

Aftertreatment Comparison

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Cummins TWC

HeatedDEF Tank DEF

Dosing Control

Unit

ECM

SCR Catalyst Particulate Filter

ISL9(diesel)

ISL G(natural gas)

Three Way Catalyst

Maintenance – ISL G

Maintenance is a key factor in engine life ISL G maintenance intervals are established by Cummins

Engineering and are based on engine family data. Key interval is oil drain, which is duty cycle dependant. The ISL G durability target for major engine components

(crankshaft, etc.) is the same as ISL– B50 of 600K miles / 20,000 hours in typical on-highway

applications (30 mph average speed). However, not all engine components have the same life

expectation. In particular, the ISL G engine 2 valve cylinder head – Predicted B50 life of 325K miles (11,000 hours).

Intended Service Guidelines The ISL G operates in a variety of applications. Maintenance intervals as

published by Cummins are established based on vehicle applications and average speed.

Normal Duty is described as idle time less than 40%, the vehicle does not operate in dusty areas, and GVW is not more than 65,000 pounds.

Vehicles exceeding the published weight values as described in Cummins AEB 140.21 require a Cummins application review.

ISL G Severe Duty Application Review Severe Duty is described as more than 40% idle time, expected annual

mileage in excess of 60,000 miles per year or weights in excess of 65,000 pounds

Severe Duty requires special consideration on a case by case basis– Severe duty may increase maintenance costs and engine life

Each case must be specifically approved by CWI.

ISL G Ratings

ENGINEMODEL

ADVERTISED HP(KW) @ RPMPEAK TORQUELB-FT @ RPM

ISL G 320 320 (239) @ 2000 1000 (1356) @ 1300

ISL G 300 300 (224) @ 2100 860 (1166) @ 1300

ISL G 280 280 (209) @ 2000 900 (1220) @ 1300

ISL G 260 260 (194) @ 2200 660 (895) @ 1300

ISL G 250 250 (186) @ 2200 730 (990) @ 1300

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Governed Speed: 2200 RPM

ISL G -Oil Drain Intervals

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OEM Freightliner Peterbilt Kenworth Volvo Navistar

Model M2 – 112SD - 114

320384365

T800SHW900ST440T470

VNM TranStar

Engine ISLG 320ISL G 300

ISL G 320 ISLG 320 ISL G 320 ISL G 320

Application 6x4 Tractor 4x2 Tractor4x2 Truck6x2 TruckVocational

TractorVocational

Mixer

TractorVocational

Mixer

Tractor Tractor

Cal Cartage, CA UPS Pac 9

Ryder TrucksDillon TransportPaper Transport

SyscoPepsicoCoca Cola

Rush Waste Management

over1,500engines in

service

North America Truck Fleets

ISL G Availability – Conventional Trucks

ISL G Availability – COE TrucksOEM AutoCar Mack Peterbilt American

LafranceCrane Carrier

Model Xpeditor TerraPro LETerra Pro CO

320 Condor LET

Fuel LNG/CNG LNG/CNG LNG/CNG LNG/CNG LNG/CNG

Engine ISLG 320 ISLG 320 ISL G 320 ISL G 320 ISLG 320

.North America Refuse Fleets

City of Los Angeles, CA City of Toronto Miller Waste, Ontario

Republic Service City of Sacramento, CA EMI, Quebec

Specialty Solid Waste Long Island, NY BFI / City of Surrey, BC

City of New York Smithtown, NY

Denver, COOgden, Utah

Waste Management (USA, Canada)Violia Environmental

over4,000engines in

service

ISL G Availability – Transit Buses

Top North American CNG Transit Fleets

over8,000engines in

service

LAMTA, Los Angeles, CABoston, MA

OCTA, Orange County, CAWashington DC

Big Blue Bus, Santa Monica, CADallas, TX

TransLink, Vancouver, Canada NY / Long Island Transit, NY San Diego Transit, CA

Foothills Transit, CA RTC Transit, Las Vegas, NV HSR, Hamilton, Canada

Fort Worth, TX Santa Clara, CA

Tacoma, WA St. Louis, MO

OEM New Flyer NABI Orion ElDorado Gillig

Model 30/35/40 Low Floor 35/40 Low Floor60 BRT

Orion V HFOrion VII LF

EZ Rider II 30/35/40 Low Floor

Fuel CNG CNG CNG LNG/CNG CNG

Engine ISLG 280 ISLG 280ISL G 320

ISL G 280 ISLG 280 ISLG 280

Be aware! Compressor Oil Drop Out

– Lube oil for compressor station passing with the fuel.– Coats and fouls sensors in fuel housing.– Compounded when not draining fuel filters.– If find in one vehicle, best to inspect entire fleet.– Maintain and monitor fueling equipment with due-diligence.

Lube vs. Non-lube Compressor– Lube passing up to 60 ppm.– Non-lubed design passing 6 ppm.