8 lug hd truck - june 2015
DESCRIPTION
8 Lug HD Truck - June 2015TRANSCRIPT
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JUNE 2015
WORKTRUCKREVIEW.COM
ALTERNATIVE ENERGY SPECIAL
CNG PICKUPS FROM THE BIG THREE
PICK YOUR PROPULSION GREEN OPTIONS FOR FORDS F-59
2016 RAM
2500 HD CNG
FUELING THE FUTUREFUELINGIS GDIESEL
THE ANSWER? GDIESELS GINORMOUS FORD F-650 PG. 32
SPOTLIGHT! DURACELLS POWER FORWARD DISASTER RELIEF FLEET_
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Call Our Experts 800.509.7220 2013. AutoAnything, Inc. All Rights Reserved. AutoAnything is a registered mark of AutoAnything, Inc. All other marks are the property of their respective owners. Prices subject to change. Not responsible for typographical errors.
1,000s of Parts for Performance, Protection & StyleLARGEST ONLINE SELECTION
CONTROL YOUR LOAD ANDTHE ROAD WITH AIR POWER!FIRESTONE AIR BAG SUSPENSION KITFirestone Air Suspension gives you the power to ne-tune your suspensions rmness. Custom made for your vehicle, this air suspension kit is designed to keep your load level, improve steering control and braking, level headlight beams and even reduce tire wear.
LADDER RACKS From $22999/kit FREE Shipping
YOUR TOWING HEADQUARTERS!Mount a powerful trailer hitch to your frame and you have the freedom to haul anything, anywhere. Tow your boat to the lake or your ponies to the trackno jobs too big. Once you pick your hitch, head over to our suspension systems department to handle load-leveling duties and boostroad-going stability.
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Ford Power Stroke 6.4L
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PERFORMANCE AIR FILTERS Boost power and torque with a K&N Cold Air Intake. Custom engineered with a famous K&N Filtercharger cone lter and crosslink nylon intake tract. 10-year / 1,000,000 Mile Warranty. Easy installation.
COLD AIR INTAKES*
The washable and reusable pleated and oiled cotton gauze ltration medium runs up to 50,000 miles between cleanings, depending on highway conditions. 10-year / 1,000,000 Mile Warranty. Installs in minutes.
Estimated horsepower and torque gains based on specic or similar vehicle dynamometer tests. Results will vary. For more information, look up vehicle and/or testing protocols at knlters.com. *57 Series Intakes are 50-State Legal. Intake systems beginning with 63/69/77/RK are street legal in most states. Some of these parts are not legal for use on certain vehicles in California, or other states adopting CA emission standards. Visit us online for CARB status on each part for a specic vehicle.
6.6L Duramax ('11-'15) .................Part# 33-2466
6.6L Duramax ('06-'10) .................... Part# E-0781
6.7L Cummins ('10-'12) ................... Part# E-0787
6.0L PowerStroke w/Box ('03-'07) ... Part# E-0780
6.7L PowerStroke ('14-'15) ............Part# 33-5010
...Plus 100s More! Call or Visit Us Online.
6.6L Duramax ('11-'12) ................... Part#63-3077
6.6L Duramax ('07 -'10) .................. Part#57-3066
6.7L Cummins ('07 -'09) ..................... Part#57-1557
6.7L PowerStroke ('13-'15) ...............Part#63-2582
7.3L PowerStroke ('99 -'03) .............. Part#57-2530
...Plus 100s More! Call or Visit Us Online.
INCREASE YOUR TORQUEAND HORSEPOWER!
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FREE SHIPPING1
NO MINIMUM PURCHASE _ NO HIDDEN FEES
or Visit AutoAnything.com Up-front low prices with 1-year protection.LOWER PRICE GUARANTEE2
1. Free Shipping to Continental US only. No APO/POs. Truck, oversized & select shipments excluded. 2. Find it for less and well refund the dierence up to 1 year from purchase. Some restrictions apply. See website for complete details and restrictions.
LLOYD MATS RUBBERTITE CUSTOM ALL-WEATHER MATSNo matter what the jobsite drags in, RubberTites edge-to-edge pattern of cups catches everything from jumbo java drops to greasy grime. The underside sports an array of carpet-grabbing nibs to keep your mats in place. Crafted in the USA and available for nearly any truck in a fan deck of colors. Lifetime Warranty.
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CUSTOM SEAT COVERSNothing on your truck works harder or takes a beating like your seats. So protect your interior from that posterior pum-meling with top-of-the-line seat covers made from rugged canvas, smooth leatherette or hard-wearing neoprene. See our huge selection online.
LOOK WHAT THE JOB DRAGGED IN! YOUR SEATS WORK AS HARD AS YOU DO!
Leatherette Camo
Neoprene Canvas
$ 54 90FROM PR.
$ 139 95FROM ROW
Installs faster than any other hard tonneau cover Built from aircraft-grade aluminum with a high-strength honeycomb core
Weighs in at a mere 50 lbs. for easy handling Opens and closes fast, thanks to exclusive spring-loaded SpeedKlamps
Secure SafetyKlamps solidly latch the cover to your bed
Installs in minutes with no tools Easy to fold-up or fully remove for hauling big loads
Unique hinge design channels water away Durable Poly-Tex textured black nish resists harmful UV rays
Made with pride in the US A Backed by a 3-year warranty
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"I was blown away by how easy this install was, how snug the t, and how great the appearance. My buddy just paid almost twice as much for another brand that required him to screw mounting rails into his bed. No need for that here, just clamp it on and you're done!" - Nick E (Jacksonville, FL)
EASY FOLDING DESIGN, HARD COVER SECURITY!
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48
contents JUNE 2015Dual Fuel DuelClean burning and locally
sourced 26
FEATURES
32
48
Alternate RealitiesWhich alternative fuel should you
use in your work truck?
Lighting the WayDuracell Power Forward program
helps rebuild and recharge
42Pick Your PropulsionDriving three Ford F-59 alternative-
fuel options
Holding PowerHeavy hauling with a modded
Cummins56
PRODUCTIVITY
66The ShieldProtecting a Chevy DEF tank with
a steel skidplate
76Max-a-MillionSoCal Diesel and ATS build a 500hp
Duramax for the extra-long haul
76 56 32
GARAGE 8
MAILBAG 12
LUG NUTS 14
WORK PRODUCTS 20
READERS RIGS 90
ON THE COVER: Theres no missing
GDiesels Ford F-650
when it cruises down
the road. Rather than
a biofuel, GDiesel is an
alternative fuel made
by further refning #2
diesel with natural gas.
Photo by Steve Temple
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6 WORKTRUCK J U N E 2015
ADVERTISING
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7" Lift Kits OEM wheels can be reused Maintains OEM steering geometry Retains factory alignment spaces CNC machined steering knuckles Front and rear 1/4" steel crossmemebers Heavy-Duty raised torsion bar relocation brackets Differential skid plate All 4 bump stops are relocated 4 Nitrogen gas charged shocks included 6" Lift kits availabel C11680K
2011 Chevrolet/GMC
2500HD
C11781K
March 1 - May 31
Buy 4 M95 Shocks Get $55
Buy 4 Hydro Shocks
Get $35
Buy 4 Nitro Shocks
Get $35
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8 WORKTRUCK J U N E 2015
You Hauled it Home, Alright!
turned out to be three older women (who may
or may not have known each other very well). It
all went awry when one snatched a purse while
in a thrift store, which apparently wasnt part
of the plan. The other two wanted nothing to
do with it, at which point the snatcher hopped
in the driver seat and wellmoments later ran
into a power pole. Bloody but mobile, she left
the crash site and apparently locked herself
inside a nearby homeowners bathroom.
So there you have it. Sometimes crazy
things happen literally right in front of you.
Whats your most memorable only-in-
movies frsthand account?
Monica
That kind of stuff only happens in
movies. Thats what I thought, too,
until it actually happened. If youre
more of a visual type of learner, skip
straight to the photo. If youd like to
hear the story, bear with me for one
minute and keep reading.
We were out testing new trucks in the local
Californian desert on a sunny December Friday
afternoon. It was lunchtime (priorities), and we
had just parked the traveling circus convoy of
- and -ton trucks along the back row of a
parking lot and had been seated at a promising
Mexican restaurant. Our order had been taken
and it was setting up to be a perfectly normal
lunchtime experience with congenial coworkers.
And then it happened.
In an instant, everything got weirdbut it took
a minute for the weirdness to set in. Perhaps
youve had a similar type of experience. I kind
of heard it frst, and then, out of the corner of
my eye, I saw a U-Haul box truck come barreling
through the parking lot. It was seemingly com-
pletely out of control, and as it swung around a
corner to exit the parking lot (thankfully, instead
of crashing straight into the restaurant), the
passenger door fung open. Upon a quick weight
shift, the door slammed shut again and after
two large booms the runaway U-Haul sped away
onto a busy street. It had bypassed the exit
driveway as it passed another vehicle that was
patiently waiting for traffc to clear, driving off a
curb with reckless abandon for the planter land-
scaping and the large sign for the restaurant of
which we were patrons.
We had barely fnished recounting this odd
eyewitness experience when the power sud-
denly fickered a few times. Then, as someone
pointed at a swaying power line outside, the
power went out completely. It took a few
seconds, but then it hit our whole group at
almost the same time as we all simultaneously
muttered the same words to each otherthe
U-Haul! It didnt make sense and it couldnt be
(because that kind of thing only happens in
movies). Moments after the power went out,
sirens could be heard from very close by, and a
U-Haul pickup was dispatched from the U-Haul
site, which was ironically right across the street.
We ran outside to see how close the action
was. Most of the group stayed put (who wants
to be caught in the middle of a gun fght or
something truly crazy like that) while a few
brave ones who couldnt resist the journalistic
instinct to investigate proceeded toward the
scene. The tales they returned with would have
had essentially brought the whole city to a
standstill.
The resulting newspaper report further
muddled the weirdness factor of the chain of
events we had observed. I suspected someone
had stolen the U-Haul (which was presumably
packed to the brim with someones valuables)
spontaneously from the parking lot. However, it
been dismissed as grandiose hyperbole if not
for the photographic evidence. It was confrmed
that the culprit was indeed the U-Haul, which
had reportedly made it not so far as the next
big intersection before centerpunching a tele-
phone pole, moving the base of the massive
pole 6 feet and causing great tension on the
live wires above. The passenger door had, of
course, fung open again, but there was no sign
of the driver.
In case you were wondering, the power was
temporarily restored long enough for us to get
our food and enjoy the rest of lunch. By the
time we left, the street was completely closed
in both directions and the power was off again
for the foreseeable future. The mini disaster
GARAGEB Y M O N I C A G O N D E R M A N P H O T O : B R E T T T . E V A N S
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Mailbag
Life After Making the Cover
Im from Gandeeville, West Virginia, and
my 81 Chevrolet K-30 is a vital part of my
workday. I use it to access remote locations to
install and repair natural gas pipelines that run
all across the United States. It has a .030-inch-
over 454 with a four-speed transmission
and 4.10:1 gears. It is a true work truck. It
has a 4-inch lift from Superlift Suspension
Systems with an additional 2-inch lift block in
the rear, and six 33-inch Super Swamper Irok
non-directional tires mounted on Rockstar
wheels from National Tire & Wheel. The truck
weighs in at 8,400 pounds, loaded with my
08 Lincoln Electric 300D welding machine and
all my tools. It has a dual 3-inch exhaust with
B Y M O N I C A G O N D E R M A N P H O T O : M A T T L U P A R D U S
Flowmaster Super 10 Series muffers. This
truck can access areas where most people
wouldnt think about taking their trucks. Thank
you for considering my K-30 for your maga-
zine. I have had my 11 Duramax on the cover
of your magazine and my 07 Cummins in the
Readers Rigs department, and it has been an
honor every time to be in your magazine.
Matt Lupardus
via Facebook
INK
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Have a comment, question, or suggestion? We want
to hear from you! Write to us at [email protected]!
Find us: facebook.com/WorkTruckReview.
the
Lupardus
acebook
When we saw your 81 Chevy, we just couldnt
resist givin your ride some inkyes, for the third
time. Its not every day that you see a work-ready
square-body third-gen GM. What a beast! A brief
afternoon Internet search has uncovered two 81
K-30s for sale locallya wrecker tow truck for
$12,500 and a utility truck with an onboard crane
and tire-changing machine for $12,900. Alas, the
budget does not allow for such expenditure, so
for now well just enjoy yours. We cant wait to see
what you send us next, although were running
out of different ways to show off your rides! For
those of you wondering how Matts done it three
times, its kind of simple. First, have a cool work
truck. Second, reach out to us through Facebook,
snail mail, or email. Third, be patient. Bonus:
Become a photographer (even if its just for a day)
and take a few dozen high-resolution photos of
your rig, paying attention to the background and
lighting. You can do it! Plus, someday youll regret
not having a good collection of photos of your
work rig.
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14 WORKTRUCK J U N E 2015
Lug Nuts NEW, INTERESTING, AND FUN THINGS ABOUT WORK TRUCKSB Y T O R I T E L L E M
ALL-NEW RAM LARAMIE LIMITED
Looking for luxury in your work truck? Ram has a new top-o-the-line
Laramie Limited, and perhaps the biggest thing to discuss amongst your-
selves is the new grille design for this Ram. Do we like or hate? Beyond
that, the truck is all about the leather; real-wood interior; chrome-inspired
exterior; new, 20-inch forged, multisurface-aluminum wheels; and a tailgate
redo. Get the package on the 1500, 2500, and 3500 models.
We are committed to using every tool in our boxenforcement,
education, and engineeringto save lives and make our streets safer.
Installing side guards on our city trucks will help prevent fatal collisions.New York City Mayor Bill de Blasio, regarding the retroftting of more than 200 city medium-duty trucks with side guards,
or rails between the front and rear wheels to protect pedestrians and bikes from getting caught underneath.
Theyre already in existence in Boston, Portland, and some other cities.
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BI-FUEL PROPANE FOR LAW ENFORCEMENT
Alliance AutoGas and BSI, a vehicle
platform developer, have created
the Bi-Fuel Propane AutoGas Ford
Interceptor conversion. Switching
to bi-fuel means no drilling, cutting,
or splicingits plug-and-play. The
result? An extra 21 gallons of fuel. Itll
be available in the spring.
16 WORKTRUCK J U N E 2015
Lug Nuts
BRIDGESTONES NEW WEBSITE FOR COMMERCIAL TIRES
Theres a new website on the Interwebs. Bridgestone Commercial has
launched daytontrucktires.com for its Dayton commercial truck tire lineup.
On the site, youll fnd a dealer tool, news, maintenance, a tire learning
center, and loads more.
Lug Nuggets The 15 Ford F-150 was named North American Truck of the Year
by U.S. and Canadian journalists.
Word is the next-gen 16 Ford F-650 will have a Landi Renzo
dedicated CNG system.
International WorkStar vocational truck now has a Cummins
ISB6.7 engine, the second WorkStar to get the option since the
DuraStar in December 2013.
Reading Truck Body turns 60 years old in 2015. You can go
through a history lesson at readingbody.com/about/history, like
how in 1970 it introd the Saddle Mate parts/tool carrier, and how
1981 brought about the industrys frst all-aluminum truck body.
Another big b-day in 2015: Allison Transmission. It turns 100
years old.
POSTAL SERVICE NEEDS NEW VEHICLES
The U.S. Postal Service is in need of a new van since its current feet of
delivery vehicles is said to be falling apart. Were talking about the need for
many of themaround 180,000 vehicles. So, who will it be? Ford? Ram?
GM? Mercedes-Benz? The bidding war has begun, and the contract is worth
a few billion bucks.
DYNATRAC TRUCK/TRAILERKind of majorly digging axlemaker Dynatracs truck/trailer wrap, inspired
by its ProRock axle. The 48-footer is made up of a 78 Peterbilt 379 with
an extended hood. Its actually been the companys rig for nearly a decade,
and it is often converted to a product display at events.
HYUNDAI TO BUILD COMMERCIAL TRUCKS
Watch for Hyundai to spend close to $2 billion to bring commercial
vehicles to the U.S. within the next fve years. In that same time frame,
it also plans to ramp up production of trucks, vans, and buses in Korea.
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www.TransferFlow.com 1-800-826-5776 [email protected]
We Fuel Your Adventures.
PHOTO COURTESY OF KELLY FROMM
Whether its a larger replacement tank, an in-bed
auxiliary tank, or a US DOT legal refueling tank, a Transfer Flow
fuel tank gives you the freedom to fuel your truck when and
where you want! Youll save time and money bypassing those
expensive fuel stations and lling up where fuel costs less.
Transfer Flow fuel tanks are made from sturdy aluminized steel
and bright aluminum diamond plate, and can be installed at over
325 locations in the U.S. and Canada. Call or visit our website for
an installer near you.
Get more fuel. Get more freedom. Get a Transfer Flow fuel tank
installed on your truck today!
REFUELING TANKS
REPLACEMENT FUEL TANKS
IN-BED AUXILIARY FUEL TANKS
Fuel Up When You Want To, Not When You Have To!
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Down-Low TonneauTonneau covers provide many benefts, including cargo security, cleaner
styling, and better aerodynamics. The BAK Industries Revolver X2 offers
those improvements in a lightweight, roll-up package. The aluminum
hard-rolling cover can withstand up to 400 pounds of evenly distrib-
uted weight, and the vinyl lining makes it resistant to dents, scratches,
and wear marks. It mounts within your truck bedrails, preserving your
vehicles clean profle. It also means that when your tailgate is locked,
your stuff is secure.
BAK Industries
818-365-9000 bakindustries.com
20 WORKTRUCK J U N E 2015
Work ProductsB Y B R E T T T . E V A N S
New-Truck FeelThe Ram pickup is a great truck in many ways, leaving no room
for a dashboard pad that cracks easily. Luckily, LMC Truck
offers a factory-ft, high-quality dash pad for the 02 to 05
Dodge Ram. LMC uses improved thermoplastic compounds in its
dash tops, which better resist shrinking and fading, keeping your
dash looking nice longer and making your truck feel brand-new.
Available in all three factory colors and with new A-pillar seals, the
new dash tops will ft right into your trucks interior.
LMC Truck
800-562-8782 lmctruck.com
First Step to High PerformanceIf youre going to use larger-than-stock valves in your Duramax
6.6L, Brodix has you covered with its WD Series cylinder heads.
With a relocated valve centerline, the WD Series allows for upgrad-
ed valves, and a unique port design provides better airfow and
more horsepower, resulting in better performance. The A-356
aluminum heads also incorporate injector cups for the LB7,
making them a true bolt-on proposition for 6.6L Duramax trucks.
Brodix
479-394-1075 brodix.com
Room to SpareDaystars Cam Can Trail Box is a new, convenient way to transport gear,
tow ropes, cables, or chains. Whether you affx it to the center of your
rear-mounted spare tire or attach it using the optional universal bracket,
the hinged, lockable box is a perfect place for small-yet-important gear.
Daystar backs up the Trail Box with a lifetime warranty, so it should with-
stand years of hard use on your weekend Jeep or daily work truck.
Daystar Products
800-595-7659 daystarweb.com
8LGS-150033-PROD.indd 3/31/15 8:02 AM PAGE 208LGS-150033-PROD.indd 3/31/15 8:02 AM PAGE 20
-
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22 WORKTRUCK J U N E 2015
The Coolest Propane AccessoryConverting a truck to run on propane is usually a tricky
job. Alliance AutoGas has simplifed the process with its
conversion kit for the 3.7L V-6 Ford Transit. A simple wir-
ing loom connects to the factory harness, while a new,
drill-free injection system sits between the intake ple-
num and the cylinder head. After just a few hours labor
(compared to several days for other kits), your Transit
is ready to run on cheap, clean-burning propane, and
Alliance backs it up with a 5-year/100,000-mile warranty.
Alliance AutoGas
228-215-0544 allianceautogas.com
Iron Fist in a Shielded GloveWelding is something that requires concentration and precision, which is why
Heatshield Products Glove Armor is worth a look. The low-profle shield fts around
the heel and pinky of most welding gloves (where its most needed), allowing the
welder to stay in the zone longer for better welds and more effcient work. It can
withstand constant temperatures of 1,800 degrees without meltingunlike most
welding glovesand it secures around your wrist for safe, trouble-free work.
Heatshield Products
800-750-3978 heatshieldproducts.com
More Points, Better PerformanceAccording to Amsoil, most diesel fuel has a
cetane number of 45 points, while most die-
sel engines work best when burning fuel with
a cetane number of 50 or more. To close that
gap, the company offers its Diesel Cetane Boost
fuel additive, which boosts that magic number
by seven points for ideal performance, smooth
idling, and improved cold starting. The additive is
also emissions and DEF compliant. Its now avail-
able in a -gallon size, which is good to treat up
to 50 gallons of diesel. Amsoil
800-956-5695 amsoil.com
Work Products
Keeping FrostyNow that summers here, youre going to want
to keep cool and refreshed by any means neces-
sary. Dometic Group can help with the all-new
CRX 50 refrigerator. Ideal for Class 8 trucks, the
CRX 50 is a rugged, built-in way to keep sports
drinks, water, and power-lunch leftovers cool.
Additionally, it can be easily transformed from
refrigerator to freezer, keeping things as cold as
17 degrees. Low power consumption and elec-
tronic, rather than mechanical, internal controls
provide economical, reliable operation.
Dometic Group
800-544-4881 dometic.com/truck
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W129000-8LGS-150033_R.pdf 10:10:10 AM__03/27/2015 Ad Insertionblackyellowmagentacyan
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26 WORKTRUCK J U N E 2015
CLEAN BURNING AND LOCALLY
SOURCED
B Y J A S O N G O N D E R M A N P H O T O S : J A S O N G O N D E R M A N & R O B E R T G U I O
We are living in an era of change, and theres no
way around it. Everywhere you look people are
trying to live greener. Were more focused on
saving money now than in generations past.
And as a society, we have begun championing
the cause of decreased dependence on foreign
oil sources. Those are all good things, in and
of themselves. However, it would seem that a lot of time and resources
are being diverted into energy sources that are either highly expensive,
give little return in the way of reducing environmental impact, or are still
heavily dependent on foreign manufacturing. Fortunately, there is an
alternative thats been hiding in plain sight all these years.
Compressed natural gas (CNG) is cleaner burning than conventional
gasoline or diesel, oftentimes costs signifcantly less, and the majority
of what we use is sourced right here in North America. CNG-powered
vehicles are nothing new. People have been converting internal-
combustion engines to run on the fuel for decades, along with a
select few manufacturers who have offered factory-installed systems
(such as the Honda Civic CNG). The newest trend has become the
Dual Fuel Duel
bi-fuel option, which allows a vehicle to run on either gasoline or CNG.
Fortunately for us, the largest market utilizing this technology is pick-
ups. Currently, all three of the U.S. pickup manufacturers offer a CNG
option, and we were recently handed the keys to two of them.
The -Ton Player Ford has offered a gaseous engine prep package for the 6.2L V-8
engine equipped in the F-250 and F-350 for several years now. This
allows upftters to install either a CNG or propane (LPG) fuel package,
along with being bi-fuel capable. The big news, however, comes from
the 14 F-150. Ford has entered the market as the only company with a
-ton capable of running on CNG.
Ticking the box for the CNG option means youll be limited to the
entry-level 3.7L V-6 engine. This mill churns out 302 hp and 278 lb-ft
of torque and, unlike other models, doesnt de-rate engine power when
running on CNG. Enabling the engine to last while running on the gas-
eous fuel are a set of hardened intake valves and valve seats. The bi-
fuel hardware is provided and installed by one of several Ford Qualifed
Vehicle Modifers (QVMs)in this case it was Altech-Eco.
full
gest
the
makes
to
engines
For
than
tently
with
gauge,
dash
on
puts
on
A
the
CNG
The
make
ate
8LGS-150033-CNG.indd 3/31/15 8:06 AM PAGE 268LGS-150033-CNG.indd 3/31/15 8:06 AM PAGE 26
-
J U N E 2015 WORKTRUCK 27
BURNING Y
CED
Duel
a
when
Qualifed
During our time with the truck, we made it a point to burn multiple
full tanks of both gasoline and CNG, for the best comparison. The big-
gest takeaway was that while the 3.7L V-6 has more horsepower than
the previous generation 5.4L (302 versus 300), the lack of torque
makes the truck feel very sluggish off the line and when passing. True
to Fords word of not de-rating power output when huffng CNG, the
engines power delivery felt no different between the two fuel sources.
For light-duty work and mostly highway cruising, the powertrain is more
than adequate. When comparing fuel economy, we were able to consis-
tently best that of gasoline when running on CNG.
Switching between the two fuels is simple. The Altech-Eco kit comes
with a switch (mounted near the headlight knob) and a CNG level
gauge, which gets placed where the coin holder on the two-wheel-drive
dash is located (the same spot as the transfer case selector knob
on four-wheel-drive models). Flipping the switch from GAS to ALT
puts the system into CNG mode, which is indicated by a green light
on the switch (it sometimes takes a minute or two for the fuel system
change to occur). The switch from one fuel to the other is seamless,
only noticeable to the driver and occupants as a very slight change in
engine sound. If the CNG tank should happen to run empty, the system
automatically switches back to gasoline.
Overall, the Ford F-150 is a perfect candidate for the bi-fuel
conversion. Fuel economy is excellent, giving a great return for the
2014 Ford F-150 XLT 4x2 BASE PRICE: $34,955
PRICE AS TESTED: $47,369
CNG SYSTEM COST: $7,779
ENGINE: 3.7L V-6
TRANSMISSION: Six-speed automatic
HORSEPOWER: 302 hp at 6,500 rpm
(gas & CNG)
TORQUE: 278 lb-ft at 4,000 rpm (gas & CNG)
FUEL CAPACITY: 26 gallons
CNG CAPACITY: 15.7 gasoline-gallon-
equivalent (3,600 psi)
OBSERVED FUEL ECONOMY: 15.37 mpg
(gas)/18.23 mpg (CNG)
A toggle mounted near the light switch is used to select
the fuel of choice on the F-150. A green light indicates
CNG is being used.
The factory coin holder is removed from the F-150 dash to
make way for the CNG level gauge. Tank levels can fuctu-
ate not only with use, but also due to ambient heat.
Fords 3.7L V-6 is ftted with Bosch natural gas injectors and an Altech-Eco fuel rail. A separate fuel control module
takes over engine operation when CNG is selected.
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28 WORKTRUCK J U N E 2015
DUAL FUEL DUELother
often
happen
will
this
well-populated
$1
(depending on the cost of gas at the moment), the conversions themselves
are
dreds
This
years,
future.
structure
investment, and power is not affected by switching fuel sources. If you
dont need the size or capability of a -ton in your CNG feet, the F-150
is the perfect option. While there will not be a 15 F-150 CNG, we hope
to see its return in the future.
The Heavy Hitter Much like its competition, Chevrolet isnt new to the CNG bi-fuel game.
Fortunately for us, it has continued to offer the upft on the new-body-
style 15 Silverado 2500HD and 3500HD (single-rear-wheel only). The
bi-fuel HDs are equipped with a special version of the 6.0L V-8 gasoline
engine, featuring hardened valves and seats. When running on old-
fashioned 87-octane, the engine churns out 360 hp and 380 lb-ft of
torque. However, unlike the F-150, when the fuel source is switched to
CNG, power output is reduced to 301 hp and 333 lb-ft of torque.
The biggest downside to running on natural gas with the Silverado
is the reduction in power. On a truck as big and heavy as this, that 59
hp is dearly missed. However, we did notice
the same phenomena as the Ford wherein
fuel economy actually increased in real-world
driving conditions while running on CNGand
quite signifcantly, we might add.
Integration of the activation switch and fuel
level indication was the best we had seen. One
of the instrument panel toggles serves as the
fuel selector, and fuel level is indicated either
in the digital information display or on the physical fuel gauge, depending
on the mode. When in CNG mode, its level is displayed on the physical
gauge while the gasoline level can be found in the DIC, and when running
on gasoline, the gauges switch places.
GM uses members of its Tier-One supplier network to install the
bi-fuel system on its prepped trucks. The work is done at a secondary
location, and when complete, the vehicles are delivered by the dealer
network to the customer, as would be the case with any truck. Also, all
the major CNG components carry GM part numbers, making replace-
ments available through the GM dealer network parts departments.
If you need a big CNG truck that can do work, this is it. Whether
running on CNG or gasoline, its conventional tow rating is unaffected
and remains 13,000 pounds (when the 4.10 gear ratio is selected).
Combine this with the excellent fuel economy and superb integration,
and youve got an instant winner.
The Downside Not everything about CNG is rosy. For starters,
the tanks are quite bulky, taking up about half of
the pickups bed space (precluding ffth-wheel
and gooseneck towing). This is true for all cur-
rent models. In the future, underbed storage may
become a reality, but for now, we must deal with
the lost bed space. Then theres the matter of
fueling. While more mainstream than any of the
2015 Chevrolet Silverado 2500HD 4x4 BASE PRICE: $42,655
PRICE AS TESTED: $58,800
CNG SYSTEM COST: $9,500
ENGINE: 6.0L V-8 (LC8)
TRANSMISSION: 6L90 six-speed automatic
HORSEPOWER: 360 hp at 5,400 rpm
(gas)/301 at 5,000 rpm (CNG)
TORQUE: 380 lb-ft at 4,200 rpm (gas)/333
lb-ft at 4,200 rpm (CNG)
FUEL CAPACITY: 36 gallons
CNG CAPACITY: 17 gasoline-gallon-equivalent
(3,600 psi)
OBSERVED FUEL ECONOMY: 10.35 mpg
(gas)/14.90 mpg (CNG)
A special version of the 6.0L Vortec V-8, designated LC8,
powers the Silverado HD. Hardened intake valves and
seats are needed to allow the use of compressed natural
gas due to its lack of inherent lubrication.
The Silverados bi-fuel system integration is one of the best in the industry. Activation is done with a factory dash-
mounted switch and fuel levels are monitored in the instrument cluster.
2016Upart
not
even
this
this
pickups
bi-fuel
limited
later
few
wheel-drive
Ram
CNG
Factory-builtas
8LGS-150033-CNG-R1.indd 4/2/15 10:48 AM PAGE 288LGS-150033-CNG-R1.indd 4/2/15 10:48 AM PAGE 28
-
J U N E 2015 WORKTRUCK 29
other alternative fuels, CNG is still relatively hard to come by. Stations are
often hidden in dark industrial alleys, well off the beaten path. If you do
happen to find a good filling station, theres always the chance the pump
will either not work or give an incomplete (lower pressure) fill. We found
this to be the case about 50 percent of the time. And if youre outside of a
well-populated urban area, all bets are off.
We cant forget about the cost, either. While CNG typically runs between
$1 and $2 a gasoline-gallon-equivalent (GGE) less than regular unleaded
(depending on the cost of gas at the moment), the conversions themselves
are very expensive. The trucks need to remain in serviceracking up hun-
dreds of thousands of milesto see the initial purchase price recouped.
This solution is definitely not intended for lighter-duty consumers.
Its our opinion that CNG usage is only going to expand in the coming
years, and it just might be the internal combustion fuel of choice in the
future. However, were easily half a century away from having the infra-
structure in place for this to become a reality.
depending
running
all
may
While rare, we managed to find a CNG pump at an Arco gas station near Palm Springs,
California. The most reliable station weve found to date is run by Clean Energy and is
located near the Los Angeles International Airport.
(formerly the Chrysler Group) and built on the same assembly line as
its non-CNG counterparts at the Saltillo, Mexico plant.
The truck is not a full-CNG conversion and, therefore, it is not
eligible for Californias coveted white sticker, which allows single-
passenger carpool lane access. It is a bi-fuel conversion, meaning
the truck can run on gasoline or CNG and is equipped with tanks for
both fuels. Although a small amount of gasoline is used upon startup
of the modified 5.7L Hemi V-8, the engine runs exclusively on CNG
so the operator doesnt need to switch between fuels. The system
automatically and seamlessly switches to gasoline once the CNG
tanks are depleted. A CNG-specific gauge in the instrument cluster
accompanies the regular gasoline fuel gauge. A specific set of engine
modifications allows the Hemi to run on both CNG and gasoline:
redesigned cylinder heads, a second CNG-specific fuel rail and injector
set, unique spark plugs, and a distinct powertrain control module.
Two ultra-strong, frame-mounted, 4.6-cubic-foot CNG tanks are
mounted at the front part of the 8-foot bed, giving an effective
usable bed length of 4 feet, 8 inches. They provide a gasoline gallon
equivalent (GGE) of 18.2 gallons, with a claimed CNG-only highway
range of 301 miles. An 8- or 35-gallon gasoline fuel tank supplies
gasoline storage and extends the range to 966 miles (when equipped
with the available 35-gallon gasoline tank).
The Ram 2500 CNG has a 1,580-pound payload and 7,650-
pound towing capacity, and it comes standard
with four- and seven-pin trailer connectors and
a Class IV hitch receiver, as well as an integrated
trailer brake controller. The truck is covered by
Rams 5-year, 100,000-mile limited powertrain
warranty, with the ancillary CNG hardware (such
as the tanks and fuel filler) covered by the trucks
3-year, 36,000-mile bumper-to-bumper warranty.
The new configurations of the Ram 2500 CNG will be
available for purchase in the later part of 2015.
2016 Ram 2500Unless you deal with fleet pickup trucks on a regular basis or happen to have spotted one of these unicorns on the road, you may be part of a large group of diesel and gasoline pickup enthusiasts who do
not know that a Ram 2500 HD CNG (compressed natural gas) pickup
even exists. While the alternative fuel buff may have nerded-out on
this now-outdated news flash, Ram recently announced it will expand
this bi-fuel trucks offerings, showing the demand for alternative fuel
pickups is definitely alive and kicking. Ram first offered its factory-built
bi-fuel Ram 2500 CNG truck in 2012, as a fleet truck with availability
limited to only one configuration: a 4x4 crew cab longbed. Six months
later, the truck became available to retail customers. Flash-forward a
few years, and Ram will offer the 2500 CNG in regular cab and two-
wheel-drive configurations.
It is noteworthy to highlight a fact that could easily be overlooked:
Ram is the only North American manufacturer to offer a factory-built
CNG pickup, in contrast to third-party upfitter package offerings.
Factory-builtas in OEM, fully engineered and tested by FCA US
B Y M O N I C A G O N D E R M A N & E D W A R D A . S A N C H E Z
P H O T O : C O U R T E S Y O F T H E M A N U F A C T U R E R
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32 WORKTRUCK J U N E 2015
Alternate RealitiesWHICH ALTERNATIVE FUEL SHOULD YOU USE IN YOUR WORK TRUCK?
Despite the predominance of petroleum-based fuels, a
number of alternative fuels have been experimented with
over the last century or so. Rudolf Diesel, the inventor of
the engine bearing his name, initially envisioned using
unrefined oil. Henry Ford felt ethanol would be the fuel of
choice for his Model T, noting that fuel could be fermented
from fruit, weeds, or sawdust. (And recent research
indicates gasoline can also be made directly from sawdust.)
During WWII, German engineers ran military vehicles on a dirty coal
oil. In recent years, biodiesel made from animal fat and vegetable oil
has also caught on and is now accepted as a blending fuel in small
percentages. Weve even heard of fuel made from some really strange
feedstocks, such as dirty diapers, pig manure, or dead cats (were not
kidding here).
Obviously, work truck owners cant tolerate a substandard quality
of fuel from a suspect feedstock, since their livelihood depends on a
reliable, clean-running vehicle with a minimum of downtime for mainte-
nance and repairs. So its of practical value to take a look at some of the
latest data on fuel research and direct experience with various types of
fuels. Well focus on diesel alternatives in particular, since diesel engines
are more commonly found in heavier-duty vehicles. Well start with a
brief overview of the various alternative fuels available and then relate
the experiences of a manager of a large fleet of municipal work vehicles.
Some might confuse biodiesel with straight vegetable oil (SVO). While it
is possible to burn SVO in some diesel engines, it typically requires using a
heated, secondary tank to thin it out. Also, newer, high-pressure fuel injec-
tors cant handle the high viscosity of SVO. So thats really not an option
for late-model work trucksand will void the engine warranty as well.
B Y S T E V E T E M P L E P H O T O S : S T E V E T E M P L E
chemical
cle.
a
first
nol,
hydroxide.
esters
years,
expect
various
provides
8LGS-150033-GDIES.indd 3/31/15 8:09 AM PAGE 328LGS-150033-GDIES.indd 3/31/15 8:09 AM PAGE 32
-
Vehicle Manager Dave Johnson has found GDiesel to per-
form better in a variety of conditions and work trucks
and it requires less maintenance.
J U N E 2015 WORKTRUCK 33
Realities
the
engines
vehicles.
a
-
In contrast, biodiesel is extracted from vegetable oil through a proven
chemical process (see sidebar) and requires no modifications to your vehi-
cle. Without getting too technical, the manufacturing of biodiesel involves
a chemical term called transesterification. In this process, the fat or oil is
first purified and then reacted with an alcohol, usually methanol or etha-
nol, in the presence of a catalyst such as potassium hydroxide or sodium
hydroxide. When this happens, the triacylglycerol is transformed to form
esters and glycerol. The esters that remain are what we call biodiesel.
A number of refiners have gotten into the biodiesel field in recent
years, with more than 1.1 billion gallons produced in 2012. So you can
expect to see growing use and availability of biodiesel.
Even though biodiesel contains no petroleum, it can be blended at
various levels with petroleum diesel. As little as 2 percent biodiesel
provides additional lubrication (Scheid Diesel adds biodiesel to its race
The difference in
clarity between
GDiesel (right)
and conventional
#2 diesel is
obvious.
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34 WORKTRUCK J U N E 2015
ALTERNATE REALITIES
New Emissions Research on GDieselTo make things clear (literally in this case), GDiesel is not a biofuel, but an EPA-approved
alternative fuel made by further
refning of #2 diesel with natural
gas. It is produced by ARC
(Advanced Refning Concepts)
in northern Nevada, and the
process starts by pressurizing
and slightly heating diesel in
a steel tank. Then natural gas
is piped in and the resulting
mixture swirls up and through a
wheel-shaped flter wrapped with
four different metal catalysts
that cause the two fuels to
bond together. After further
fltration, the fnal GDiesel fuel
has shorter-length hydrocarbon
molecules that combust more
completely than longer-chain
molecules, akin to throwing
smaller pieces of wood on a fre
rather than a big log.
While ARC makes no claims
about improvements in fuel
effciency, weve seen a number
of independent reports from
feets using GDiesel that
indicate improvements in mpg
range from 10 to 35 percent,
depending on the engine
and vehicle. Veteran off-road
competitor and instructor Rod
Hall found that GDiesel greatly
improved the fuel effciency of
his schools Humvee trucks. And
weve personally measured a 21
percent gain in a 96 Dodge Ram
with a 12-valve Cummins.
In addition, we also came
across some recent emissions
research by Dr. Eric A. Lutz,
published in the Journal of
Occupational and Environmental
Hygiene. This article compared
the emissions of petroleum
diesel with GDiesel and B75
biodiesel in an underground
mining operation. Since diesel
fuel is a known carcinogen
and can also cause various
respiratory ailments, fnding
cleaner alternatives is clearly
needed for greater safety in the
work environment.
More than 223,000 miners
are actively employed in the
U.S., and they rely on diesel-
powered rigs, along with
gensets and other heavy
equipment. Despite ventilation
and administrative controls,
levels of underground diesel
particulate matter frequently
exceed legal standards. Using
an 05 Wagner B10-203 LHD
vehicle as a testbed, Dr. Lutz
(who serves as assistant
professor and director of mining
safety and health programs at
the University of Arizona), found
that GDiesel has a signifcantly
lower diesel particulate
matter66 percentthan
ultra-low-sulfur #2 diesel. By
comparison, biodiesel lowered
particulates by 33 percent. His
research further indicates that
GDiesel resulted in a reduction
in all other exposures (except
CO, which is typically not at
high levels for diesel fuel, ARC
notes).
fuel for this reason), and a number of major diesel engine manufactur-
ers approve of percentages ranging from 5 to 20 percent (referred
to as B5 and B20). In some cases, biodiesel is used as the sole fuel
(B100). (Note, however, that running pure biodiesel might void an
engine warranty claim.)
While biodiesel furnishes similar fuel economy, horsepower, and
torque as regular dieselalong with signifcantly reduced emissions
not all fuel experts and work truck operators prefer it. We spoke at
length with Dave Johnson, manager of the Automotive Services Division
for Clark County, Nevada, whos in charge of a feet of 2,800 municipal
vehiclesabout 1,500 of them diesel (approximately 75 percent pick-
ups). Since using alternative fuel is mandated by the State, Johnson
has extensively tested and compared three different types: B5 bio-
diesel, oxydiesel (an ethanol/diesel blend), and GDiesel (see sidebar).
Johnson has used all of these fuels in a variety of vehicles and in
various temperature extremes, from shuttle buses on the tarmac
at McCarran airport in summer heat to snowplows at nearby Mt.
Charleston in freezing weather.
The bottom line? He favors GDiesel from ARC (Advanced Refning
Concepts) over the other three types of fuel, for a variety of reasons.
Its never gelled once at Mt. Charleston in cold weather, he says. Thats
not the case with B5 or #2 diesel, both of which require cold-weather
additives during the winter. Even with the additives, he notes that his
biodiesel-fueled rigs are typically harder to start in cold weather.
Oxydiesel is much more volatile, but in the summer heat of Las
Vegas, its much lower fash point requires using spark arrestors, and
other safety precautions, Johnson points out. He also found that some
vehicles running oxydiesel wouldnt restart at the airport until they
cooled off for a few hours.
Johnson notes other drawbacks of using B5: It makes black smoke
Peter Gunnerman of Advanced Refning Concepts, pictured atop his refnery near
Sparks, Nevada, says his frm is evaluating new ways to increase the output and dis-
tribution of GDiesel to keep up with increasing demand.
Producing GDiesel begins with heated and pressurized #2 diesel, which is catalyzed
with natural gas to form a much cleaner, lighter, higher-quality fuel.
8LGS-150033-GDIES.indd 3/31/15 8:09 AM PAGE 348LGS-150033-GDIES.indd 3/31/15 8:09 AM PAGE 34
-
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36 WORKTRUCK J U N E 2015
ALTERNATE REALITIESin back, and I have to clean the storage tanks twice a year, instead of
just once a year with GDiesel, as a precaution. Filters need to be changed
more often as well, usually every 30 days, both of which add to his oper-
ating expense and maintenance downtime. As the flters get clogged
with particulates, the storage tank pump slows down, too. Its a real
pain, he adds.
Regarding repairs on vehicle engines, Ive lost fuel pumps and injec-
tors with B5, Johnson notes. Ive never had a [mechanical] issue with
GDiesel. That aspect is particularly a concern with the emergency
vehicles (fre trucks and ambulances). GDiesel is a premium fuel in my
opinion, he adds. Its worth every penny.
At this stage, GDiesel has only limited availability. Its sold mostly
to construction and agricultural accounts, and a few retail stations in
Home-Brewed Biodiesel?Small-scale biodiesel companies and DIY home-based operations have sprung up
in recent years. Several companies
make machines that enable you
to produce biodiesel in your own
garage or workshop on a small
scaleabout 40 to 100 gallons per
dayfor less than $1.00 per gallon
(not counting the labor involved).
A biodiesel system typically
consists of a couple of plastic
tanks with pumps, hoses,
valves, and flters, along with
a weight scale and testing
equipment. To produce
biodiesel, you frst have to
collect some waste oil and
flter out any debris. Then its
quality has to be evaluated by
titration, a simple chemical
test that determines the amount
of lye and methanol required to
convert the oil to biodiesel.
These two chemicals are
carefully mixed together in a
sealed container. This mixture,
called sodium methoxide, is
caustic and requires safety
precautions such as protective
goggles and gloves. The mixture
is added to a tank of lukewarm
oil (heat speeds the conversion
process), and after about 30
minutes, glycerin separates out
from the oil and is drained off. The
resulting biodiesel is slightly cloudy
at this point. Although it can be
burned as fuel, some systems add
another step of water washing
for further refning. This phase
uses a mister to spray water into
the oil. As the water sinks to the
bottom (since oil foats on water),
it captures impurities and is later
drained off.
Lastly, the biodiesel is pumped
through a water separator to
eliminate any remaining moisture,
and fne flters to get rid of
particles and impurities. Some
companies recommend an
additional drying stage if water
washing is used.
If youre a work truck owner/
operator and youre considering
making your own biofuel, keep
in mind a few cautions: Its fairly
time-consuming to collect and
refne a biodiesel feedstock. Its
also imperative to be safety-
conscious, since the process
requires working with methanol
and lye. Last but not least, a
by-product of biodiesel processing
is glycerol (also known as glycerin),
which requires a suitable use or
method of disposal.
Note, too, that biodiesel is
a solvent and tends to loosen
accumulated sludge, which
might clog the flter and require
replacement after running a tank
or two in an older vehicle. Also,
most pre-94 and a few later-
model vehicles may have rubber
fuel lines and/or rubber seals in
the fuel system. Biodiesel will
gradually swell the rubber and
degrade it. Its a good idea to
check under your hood periodically
and replace fuel lines and
seals with a biodiesel-resistant
synthetic, such as Viton, if they
begin to deteriorate.
In addition, for those who drive
in a colder climate, biodiesel gels at
around freezing or slightly higher,
depending on what kind of oil/
fats it was made from and the
percentage of the blend. Of course,
this clouding can be a problem for
diesel fuel in general, and the same
cold-weather additives can be used
for biodiesel as well.
Other biodiesel feed-
stocks include jatropha,
peanut, soybean, coco-
nut, and waste fryer oil.
Biodiesel can be made
from a variety of feed-
stocks, such as canola
oil (right), or even cof-
fee beans (left).
Making biodiesel in your own garage or workplace is feasible and economical but
requires some safety precautions.
The late Dr. Rudy
Gunnerman,
inventor of
GDiesel, showing
the computer
controls at his
refnery.
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38 WORKTRUCK J U N E 2015
ALTERNATE REALITIESReno. ARC is working on increasing the number of refneries and their
output volume as well, along with other applications such as refning
waste oil and producing jet fuel.
Since there are more choices than ever in the alternative fuel
field, we want to know: What fuel do you prefer for your fleet, and
why? Finally, as with any new technology, not everything works
exactly as claimed. Its wise
to confirm any refiners
promises of performance
with actual users to keep
your work truck running
reliably and clean in all
sorts of conditions.
Ethanol: Alcohol-Based FuelRecently, entertainer and car collector Jay Leno raised a question in an AutoWeek article
titled Cant We Just Get Rid of
Ethanol? Thats a reversal for
him, since not too long ago at
SEMA, he touted E85 and other
ethanol blends of gasoline with
his Z06 Vette. Lets address a
couple of objections to ethanol
that both Leno and others have
raised.
Its true that ethanol
emulsifes and holds water. But
that can be an advantage, since
gas tanks are actually drier
after the transition from E0
to E10. With straight gasoline,
whatever water is in any tank or
atmosphere phase separates
and falls to the bottom of the
tank. With ethanol-blended
fuel, however, that water will be
suspended during the driving
of the vehicle and vaporized by
the engine.
Concerns about the increased
risk of engine fres or damage
have not been substantiated
even on older vehicles. And
much testing with E0 (0 percent
ethanol) and E10 (10 percent
ethanol) shows the latter type
should not negatively affect
an old car or truck. And newer
fex-fuel vehicles are designed
to handle ethanol.
Even so, the energy content
of ethanol is lower than
gasoline, so your fuel mileage
will be reduced. On the plus
side, ethanol has a higher
octane level, so it works
well with high-compression
and either turbocharged or
supercharged engines.
Learn more at: ethanolrfa.org/
pages/ethanol-facts.
GDiesels Ginormous Ford F-650 When youre an electrician working for GDiesel refner ARC, it only makes sense to drive
a diesel truckbut not just any
rig. To really make a statement,
Chuck Bump mans the wheel of
a supersized Ford F-650.
Instead of being ftted with a
functional fatbed or cargo box
in the rear, Manning converted
the chassis cab truck into a
four-wheel-drive setup with a
pickup bed out back. The latter
mod required shortening the
framerails to 56 inches. Since
the cargo bed sits a full foot
above them, a collapsible ladder
deploys from its mounting on
the tailgate to make it easier to
climb aboard.
The four-wheel-drive
conversion was fairly involved,
with the steer-drive axle
swapped out for a Marmon-
Herrington front-drive drop axle
in a center bowl confguration
with automatic slack adjusters
for the air brakes. Double Cardan
joints were used in the two-piece
front driveline thats mated to
a Marmon-Herrington MVG750
two-speed transfer case with an
air-shift mechanism.
This setup has some specifc
requirements. Only a 43B or 43C
OEM front axle can be used (with
the drive-axle rating the same
as the factory GAWR). Regarding
the transmission, a fve-speed
automatic is recommended, since
the top gear has to be deleted
on a six-speed unit. For exhaust,
either the 91B or 91D systems are
ftted. Lastly, this setup only works
on air-brake trucks running on
22.5-inch wheels with an air-ride
suspension and/or a high-CG body.
The Fords stock 6.7L
Cummins engine had just
18,000 miles on it when Bump
purchased it. Leaving well
enough alone, he focused his
upgrades on the cosmetics,
such as adding diamond-plate
covers on the battery boxes,
plus side and rear body trim. To
show off his employers fuel,
Bump had J&R Sign company in
Reno, Nevada, apply the GDiesel
logo wrap with the company
logo prominently displayed.
Everybody knows what kind of
fuel Bumps running when he
rumbles through town.
In Europe, where diesel is much more commonly used, GDiesel is gaining acceptance
as a preferred form of fuel. These technicians from Key Industry Engineering Group,
LLC are planning to set up a refnery in the Czech Republic.
Advanced Refning Concepts, LLC
775-826-2727
clearrefning.com
source
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42 WORKTRUCK J U N E 2015
Pick Your PropulsionDRIVING THREE FORD F-59 ALTERNATIVE-FUEL OPTIONS
The 2015 Work Truck Show in Indianapolis is the nations largest
convention of work truck manufacturers and equipment suppli-
ers. Its the perfect place for companies to show off their great-
est technologies. With a signifcant emphasis placed on green
trucks, much of that technology was focused on reducing fuel
consumption and emissions, while providing lower operating costs and
simpler feet integration to those brave early adopters.
Proving they knew how to put their money where their mouths
were, several different companies offered testdrives and rides to allow
attendees to experience their cutting-edge technology frsthand. We
were invited to drive three Ford F-59 box vans, each powered by a dif-
ferent propulsion system.
B Y B R E T T T . E V A N S P H O T O S : B R E T T T . E V A N S A N D C O U R T E S Y O F T H E M A N U F A C T U R E R S
Crosspoint Kinetics: Ford F-59 Gas-Electric Hybrid
Crosspoint Kinetics solution to the energy problem is a bolt-on, after-transmission electric hybrid system that uses compact ultra-capacitors in place of batteries for energy storage. As with most hybrid
electric vehicles, the Crosspoint F-59 uses regenerative braking to build
a reserve of potential energy. However, the system only works from 30
mph to 0, with electric boost then moving from the ultracapacitors to
the rear wheels as the vehicle accelerates to that 30-mph threshold.
At that point, the vehicle moves on its primary fuel source (gasoline,
diesel, compressed natural gas, or propane) alone.
While the hybrid system may sound a bit underwhelming com-
pared to other electric tours de force, there are a number of
benefits, including lower initial cost and more reliable operation.
Additionally, most box vans spend the majority of their time decel-
erating from and accelerating to 30 mph, so Crosspoints system
is well suited to the application. The company claims efficiency
increases of 30 percent in normal fleet van driving, with a commen-
surate decrease in greenhouse gas emissions.
In practical use, it all worked seamlessly. Regenerative braking was
unnoticeable, and the engines auto-stop was responsive when the
light turned green. Aside from the initial surprise at the gas engine
shutting down when stopped, the vehicle provided a driving experience
similar to any other box van.
Using a somewhat conventional gas-electric hybrid system, the Crosspoint
Kinetics Ford F-59 relies on ultracapacitorsnot batteriesto store energy.
That important switch is what makes the conversion relatively simple and
cheap. An engine stop-start system further reduces emissions and fuel con-
sumption, particularly in urban driving.
Roush CleanTech:
Tmuch
and
green
signifcantly
time)
Modifer
manufacturers
new
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J U N E 2015 WORKTRUCK 43
Propulsionallow
-
experience
Roush CleanTech: Ford F-59 Propane
The propane-fueled Roush CleanTech Ford F-59 was the only non-hybrid we drove at the Work Truck Show. However, propane burns much cleaner than gasoline or diesel (eliminating particulate emissions
and reducing greenhouse gas emissions by up to 50 percent), so its
green cred shouldnt be discounted. Other advantages to the fuel are
signifcantly lower fuel costs (around half the price of gasoline at press
time) and relatively simple conversion.
Additionally, Roush CleanTech recently achieved Qualifed Vehicle
Modifer status from the Ford Motor Company (a goal shared by the
manufacturers of each of the vehicles we drove), so purchasing a brand-
new, propane-powered Ford work truck is very simple.
There are a few disadvantages to propane, however, one being
range anxiety that stems from limited refueling options. Most feets
that run propane install fueling tanks within the companys motor pool,
allowing them to refuel at the home base at the end of the day. Many
trucks routes are within the range of a full tank, but still, anxiety will
linger until propane is more widely available.
The driving experience of the Roush F-59 could not have been
more conventional. Except for the vans massive proportions, it was
as simple to operate as any other vehicle. That driving feel was both
a selling point and a negative: Fleet operators who expect a can-
tankerous science experiment are instead rewarded with the same
dynamics as their current vans, but those who crave a little gee-whiz
will be disappointed.
Roush CleanTech announced a partnership with AmeriPride,
the linen supply company, which will now use propane-powered
Roush trucks in its delivery feet. Tucker Perkins, chief business
development offcer for the Propane Education and Research
Council, advocates the use of propane thanks to its cleaner burn
and domestic production compared to fossil fuels.
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Since it runs on conventional fuels, the
Lightning Hybrids hydraulic hybrid can be
tanked up just about anywhere gas or diesel is
available. However, its unique hybrid system
lowers fuel consumption and extends service-
brake life in stop-start environments, like those
of most delivery trucks.
Lightning Hybrids: Ford F-59 Gas- Hydraulic HybridIts for that group of tech-happy early adopters that the Lightning Hybrids gasoline-hydraulic system is ideal. Hybrids solution uses hydraulic fuid instead of electricity to assist the primary power source.
Once the operator touches the brake pedal, a driveshaft-mounted pump
engages, moving the fuid from a low-pressure tank to a high-pressure
tank. This creates drag, slowing the vehicle down without actually using
the service brakes, if youre careful. Then, upon acceleration, the high-
pressure tanks potential energy is released through the pump and
power transfer unit as fuid moves back into the low-pressure tank.
The company claims a break-even payback after just one month of
normal operation based on fuel cost and brake savings, since its pos-
sible to gradually brake to a stop using just the hydraulic energy recov-
ery system. As with Crosspoints hybrid, the hydraulic hybrid is really
only effective at speeds less than 30 mph, but again, thats the space
where most delivery vans do their work. Decreased greenhouse gas
emissions and better braking and acceleration come along for the ride.
Driving the Lightning Hybrids gas-hydraulic system felt a bit like driving
Ms. Frizzles Magic School Bus. The hydraulic pump and power transfer
unit whirred and hummed at low speeds, alternating between energy
recovery and assist at every move of the right foot. (To be fair, the
noises were likely exacerbated by our empty vans echo-
chamber cargo area.) Performance and braking felt
notably better, although the regenerative-
braking system was hard to modulate
smoothly. Still, it was lots of fun!
44 WORKTRUCK J U N E 2015
PICK YOUR PROPULSION
Wed love to have driven this all-electric take on the Ford F-59 by Motiv Power
Systems. Using readily available batteries, motors, and chassis, the Motiv
solution is less costly and easier to procure than other all-electric delivery-
van options. Motiv CEO Jim Castelaz says the system is ideal for predictable,
repetitive environments like sanitation vehicles and shuttle buses.
Motiv Power Systems: Electric Ford F-59 ChassisAlthough a running vehicle wasnt available to test, Motiv Power Systems took the opportunity to show off its all-electric Ford F-59 chassis. Removing the engine creates ample room for battery packs and electric motors, which can propel a chassis for about 80 miles. As with other electrics, charging can occur at off-peak times (like at night), resulting in even more operation savings.
The company has received great feedback from the city of Chicago, which uses Motivum, shall we saymotivation for some of its sanitation
trucks. This application is ideal for electrifcation, as a city route is typically well within the range of the electric system. Replacing a gas or diesel
engine with electricity cuts down on neighborhood noise and noxious emissions as well, and thats something anyone whos been awoken at 7 a.m.
by a smelly diesel garbage truck can appreciate.
The company has placed several vehicles into feets, ranging
from Ford E-450 buses to the aforementioned garbage trucks.
Motiv says its product can be optimized for any chassis from
Class 3 to Class 8, using custom battery solutions for each
application. According to Motiv, the system pays for itself in three
years compared to diesel, which is impressive given the long life
span many feet vehicles enjoy.
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-
Heavy Duty Transmission Pans and Differential Covers
Often Copied,
Never Duplicated
818.786.8325
www.mag-hytec.com
Magnetic drain plugs
Magnetic dipstick
Cast Aluminum A356-T6
Tapped for temperature probe
25 to 50 Heat reduction
ARP O-rings on Most applications
Longer service intervals
Quicker, cleaner maintenance
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48 WORKTRUCK J U N E 2015
LIGHTING THE WAYDURACELL POWER FO
RWARD PROGRAM
HELPS REBUILD AND RECHARGE
B Y B R E T T T . E V A N S A N D M
O N I C A G O N D ER M A N P H
O T O S : C O U R TE S Y O F D U R A
C E L L
If youre anything like us, you probably take electricity for granted.
When that little red battery icon fashes on your phone, all it takes
is a quick jaunt to the nearest wall outlet to restore your device.
Unfortunately, after a natural disaster, a lack of access to reliable
electricity hobbles those lines of communication, which are now
more important than ever.
The Duracell Power Forward program, which since 2011 has
provided free batteries and power to those impacted by natural disasters,
proves Duracell knows how important communication can be following a
storm, earthquake, food, or landslide. Its recent initiative includes reach-
ing more people, more quickly, by expanding its feet of on-the-ground
relief vehicles, joining up with The Weather Channel (to track storms for
optimal feet deployment), and reaffrming its commitment to Ready.gov
(to spread the preparedness message). The goal? Reach any storm site in
the
and
disaster
says Jeff
little
expanding
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The new Duracell Power Forward feet carries on the tradition of providing
free batteries to those affected by natural disasters, but now, Wi-Fi
and charging for wireless devices, among many other modern
necessities, are available to help keep families
and friends in close contact with each
other following storms, earth-
quakes, and extreme
weather.
J U N E 2015 WORKTRUCK 49
LIGHTING THE WAY
disasters,
-
in
the continental United States within 24 hours to provide batteries, Wi-Fi,
and mobile charging.
Being in the battery business, we know all too well when a natural
disaster strikes, power fails and communities arent always prepared,
says Jeff Jarrett, marketing director for Duracell. Duracell believes a
little power goes a long way in reviving hope, so we have committed to
expanding our feet and relief efforts.
The Power Forward feet of custom-built Chevrolet light- and medium-
duty trucks is equipped with lockable charging stations, Wi-Fi, and
Internet-enabled computersall ready to serve the residents of a dis-
placed community free of charge (no pun intended).
The largest of the trucks is the Manchester, New Hampshirebased
Chevrolet Kodiak 4500 Community Center, which tows a large trailer.
Primarily designed for the Northeasts crippling snowstorms and
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Since 2011, Duracell Power Forward has been on the ground providing batteries, power, and comfort to those in need. The feet has deployed to 14 disaster locations and helped more than 30,000 families by distributing more than 350,000 batteries, charging more than 7,000 devices, and providing computer access to more than 5,000 people.
Five different trucks with four different specifc purposes are used to make sure as
many people have access to reliable electricity as possible. With each application
ftted with a variety of winches, bumpers, lift kits, and emergency equipment, debris
and blocked roads are no match for these trucks.
50 WORKTRUCK J U N E 2015
hurricanes, the Kodiaks trailer is equipped with 32 charging lockers,
four on-board computer stations, two generators, and a Wi-Fi hotspot to
help maintain contact with loved ones. Additionally, a climate-controlled
community lounge gives families a place to safely gather, while four
televisions can play weather, news, sports, and childrens movies, helping
provide a sense of normalcy in a time of trial.
Joining the Kodiak in Manchester is a dualie Chevrolet Silverado
3500HD Heavy Hauler. The trucks utility bed features enough charg-
ing stations to provide power to 60 cell phones simultaneously, while a
bed-mounted TV provides weather information and on-board Wi-Fi helps
citizens connect. Additionally, a 20-amp inverter driven by four deep-cell
batteries can provide up to 500 hours of emergency power without need-
ing recharging. Obviously, the Heavy Hauler is a power source, but since
LIGHTING THE WAY
its equipped with a heavy-duty brushguard, winch, 4-inch suspension
lift, and 10,000-pound towing capacity, it can also be used to free
stranded vehicles, clear fallen trees, and haul away rubble and debris.
The Heavy Hauler also has a twin located in San Francisco, used primarily
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52 WORKTRUCK J U N E 2015
in the event of the regions all-too-common earthquakes, foods, and
mudslides.
The Silverado 2500HD Rapid Responder combines many of the same
features in a lighter-duty package, featuring charging stations, secure
charging lockers, Wi-Fi, three computer stations, and emergency tools.
Based in St. Louis, Missouri, the Rapid Responder primarily operates fol-
lowing tornadoes and foods, using a 1.5-inch lift, brushguard, and winch
to clear a safe path through affected communities.
Also serving the Midwest and South is the New Orleansbased Rugged
Responder, a massive, lifted Silverado 3500HD dualie. A Fab Fours set
of bumpers, 6-inch Skyjacker lift, and 37-inch Toyo tires provide all the
ruggedness needed for the hurricane, tornado, and food conditions.
Most notably, additional door sealing
and a high-mounted snorkel enable the
Rugged Responder to ford water nearly
5 feet deep. Those capabilities give the
truck access to even the most remote,
cut-off communities, where people will
surely appreciate more charging stations,
Wi-Fi, and an outdoor television display.
Recovery tools, storage boxes, and a cus-
tom ARE cap provide additional utility.
All the Power Forward trucks are paint-
ed in Duracells signature paint scheme.
In fact, from afar, the Kodiaks trailer
looks a lot like a gigantic D-cell battery.
The trucks stand out, which likely helps
residents of affected communities fnd
them. In the past, the feet has made its
LIGHTING THE WAY
This Duracell Power Forward Rugged Responder is capable of handling nearly 5 feet
of standing water thanks to its massive lift, 37-inch tires, additional door sealing, and
snorkel-type air intake.
The Duracell Power Forward
crew is on call for almost any
weather-related emergency
nationwide. If you see the
CopperTop trucks in your
neighborhood, you can bet
theyll be willing to help you
get your devices charged and
contact your loved ones.
way to the California Bay Area; North Carolina; Monroe,