make every school bus better. thomas busoct 4, 2011 steve d goss sanjay kumar jim lannan

Make Every School Bus Better. Thomas Bus Oct 4, 2011

Steve D Goss Sanjay Kumar Jim Lannan

Agenda

1. Update on successes

2. IC Bus ‘Fluid’ Economy Claims

3. Cummins Fuel Economy

4. How to sell Cummins

School Bus Industry Data

Industry data suggests a 5% gain in Cummins market share (50% to 55%)

Recently gained business with largest bus customer

IC Bus ‘Fluid’ Economy Claims

IC Bus published report of fuel economy testing stating ‘up to a 4.5%’ advantage vs Cummins

Cummins responded to claims outlining the points in question including:– Transmission shift calibration selections

– Aftertreatment regeneration

Avg. Diesel Price

$3.80Avg. Bulk DEF Price

$2.85

‘Fluid Economy’ also ignores the price differential

Transmission shift calibrations

IC Bus did not outline what shift calibrations were used during testing

Cummins testing validates that proper selection can result in significant fuel economy gains

Aftertreatment Regeneration

Typical regen cycle on MF 7 at approx. 135 miles– Same distance as test

More EGR = More Soot Generated = More Regens

Regenerations require the use of more fuel thus diminishing overall fuel economy

‘Fluid’ Economy

IC’s claims of ‘fluid’ economy inaccurately represent total cost of ownership

No mention of DEF consumption thus inability to analyze actual DEF usage for test

Differences in DEF and diesel fuel pricing vary significantly so need to be analyzed separately

Cummins Fuel Economy

‘Others Test. We Deliver’

Cummins and Thomas Bus both currently testing

ISB Fuel Economy Tops DTNA Testing

Freightliner M2 106with Cummins ISB (EPA 10)

Vs.International Durastar 4300with MaxxForce DT (EPA10)

Result

• 8.5% Better Fuel Economy

• 2 Regens for ISB Vs 10 for MaxxForce DT in the

14 hour test period

In Cylinder NOx Control Challenges

Fuel economy significantly compromised

Increased risk of EGR condensation

Significant increase in heat rejection

Complex system integration

Driver satisfaction significantly compromised

Power density and torque limitations


5-9% disadvantage

Combustion efficiency degradation:– Higher engine pumping losses

– Increased intake & exhaust manifold pressures

– Increased Particulate Filter regenerations

Fuel Economy Significantly Compromised

Increased Risk of EGR Condensation


Higher EGR flow produces excessive acidic condensation

Power cylinder corrosion– Rapid deterioration of lube oil

Reliability and durability compromised


20% increase

Higher EGR flow:– Multiple EGR coolers on & off engine

– Larger vehicle cooling package

– Major redesign of radiator / Charge Air Cooler / Fan systems

Significant Increase in Heat Rejection

Complex System Integration


Higher EGR flow

Air handling system

Vehicle cooling system


Higher EGR Flow– Throttle Response

Driver Satisfaction Significantly Compromised


Deterioration of 50 – 100 hp for same displacement

Higher EGR flow & EGR controls compromises engine performance

Power Density and Torque Limitations

Clean Air

DOCDPF

Bus Owners Have Two Choices for 2010

Advanced EGR

EGR + SCR After-Treatment System Setup

Tank

Catalyst

DoserAMOX Cat

DOCDPF

Intercooler

Higher heat rejection:

Larger Radiator

Larger Charge air cooler

Rad

iato

r

Emissions Control Technology

NOx is converted into N2 and H20 downstream from the engine using

a diesel exhaust fluid catalyst

Exhaust gas is re-circulated through the cylinders reducing peak combustion temperature,

lowering NOx emissions

SCR allows for a lower EGR run rate, increasing fuel economy and engine life

With emission controls moved out of and away from the engine, power generation is unhindered

EGR introduces excessive carbon and soot into the cylinder, causing pre-mature liner and piston wear

Higher EGR cooling capacity strains the cooling system, leading to shorter coolant change intervals and component failure

19

The Facts about the Fluid – DEF Properties

DEF is safe to handle and store– Non-toxic– Non-polluting– Non-flammable

DEF freezes at 12° F (-11° C). However, frozen DEF does not impact start up and normal operation of the vehicle

When stored at extreme temperatures, neither DEF nor Urea become toxic

DEF is slightly alkaline with a pH of approximately 9

Acidic pH

DEF

DEF - Myths & Facts

Navistar’s claim of ammonia level being close to 1000 ppm in a near empty DEF tank is a ‘stretch of imagination’

DEF, when heated and maintained at a constant temperature 120 degrees Fahrenheit, will very slowly start to form small amounts of ammonia

It would take over two years at this constant temperature to convert DEF into levels of 1000 ppm of ammonia

Such a situation can be probably modeled in ‘laboratory setting’ but not in the real world

Cummins ISB6.7 vs Navistar MaxxForce 7

Competitive Comparison

Cummins ISB6.7 vs. MaxxForce 7

FeatureCummins

Advantage

Displacement 6.7L 6.4L -

Configuration Inline 6 V-8Fewer parts /

better reliability

Horsepower 200 - 325 HP 200 - 300 HPBetter power

density

Torque 520 -750 lb-ft 560 - 660 lb-ftBetter power

density

AspirationOne - variable geometry turbo

(2) dual stage

turbos

Fewer parts /

better reliability

Oil change

interval

15,000 mi.

(24,000 km)

10,000 mi.

(16,000 km)Lower maintenance cost / better uptime

Engine weight (dry) 1,150 lb (522 kg) 1,225 lb. (556 kg) Lower weight

Feature Cummins ISB6.7 Advantage MaxxForce 7

ComplexitySingle VG turbo, single

radiator & charge air cooler

Dual turbos, multiple charge air coolers and radiators, large

EGR cooler

Emission Controls

Diesel Particulate Filter and Selective Catalytic

Reduction

Diesel Particulate Filter and Advanced EGR

Maintenance and Service

15,000 mile service intervals and 3,500 authorized service

locations

10,000 service intervals and 900 authorized

service locations

Competitive Comparison Summary

Designing For the School Bus Market

Reliability Total cost of ownership Low maintenance Safe Operation Sociability Performance Weight/space Minimal driver training Ease of operation Information systems Emissions compliance

Cummins Diesel Power

ISB6.7 & ISC8.3 Features

Improved combustion system

Advanced VGT Turbocharger

Improved cooled-EGR subsystem/cooling circuit

Fully integrated electronic controls

New Cummins Aftertreatment System

ISB6.7 & ISC8.3 Customer Benefits

Best-in-Class Fuel Economy

Improved Reliability

Minimal Installation Impact

Stronger Performance

Increased Power Density

Cummins Natural Gas Power

ISL G Product Features and Benefits

8.9L Stoichiometric Cooled EGR engine with spark ignition

In production since mid-2007

Low emissions

Diesel-‘like’ Performance, Reliability and Durability

Over 80% parts commonality with ISL9

Compatible with CNG, LNG, or Biomethane (RNG)

29

2010 ISL G Natural Gas

Three Way Catalyst Aftertreatment– Passive device

– Packaged as a muffler

– Maintenance-Free

Stoichiometric Combustion Cooled EGR– Same rated speed as ISL9

diesel

– 30% more torque at idle

– 5% better fuel economy

CombustionTechnology

Filtration and Diesel Exhaust Fluid

Integrating Critical Subsystems

Electronic Controls

Aftertreatment System

Turbochargers

Fuel Systems

32

PowerSpec

Software Application– Provide gearing recommendation

– Customize engine ‘specs’

– Collect valuable trip information

– Free to download and use

www.powerspec.cummins.com

INLINE™ adapter

Cummins datalink adapter used in conjunction with PowerSpec

Allows user to: – transfer feature parameter settings

– download trip information

INLINE™ 5 kit (part number: 4918416) includes all necessary parts to connect the vehicle to a laptop

33

Make Every

TM School Bus Better.

Better Fuel Economy.– Up to 3% better than our ’07 ISB and ISC

– Joint testing underway on EPA 2010 product

Better Performance.– Improved driveability and throttle

response

Better Reliability.– Best-in-class durability and dependability

Better for the Environment.– Near zero NOx and PM emissions

– Improved MPG results in smaller carbon footprint

Saf-T-Liner EFX

36

Daimler Trucks

Common Parts with HDX means faster design cycle

00000-00-Thomas Built Buses Standard Template.ppt 37

Bumper(10)

#2 Hood(2)

Front Roof Cap(6) Clearance/Marker Lights

(6)

“A” Mirrors(8)

Walk Gate(8)

Headlight & Bezel(4)

Wipers(15)

Hazard Lights(4)

Header Height/Drip Rail(4)

“B” Mirrors(8)

Destination Sign (20)

Windshield(3)

Sub-system ID (estimated number of parts to be eliminated ~100)

Daimler Trucks

Driver Focused Improvements - Storage

• Added driver’s storage to right side dash

• Can be used for safety equipment storage or for personal items


Daimler Trucks

Driver Focused Improvements - Visibility• Improved visibility

• HDX windshield• Larger driver’s side

window• Argosy headlights• Running lights

standard


Daimler Trucks

Driver Focused Improvements - Visibility• Improved defrost capability


Daimler Trucks

Technician Focused Improvements - Access

• Headlight doors and removable grill provide easy service access

• Lights• Wiper motors and linkages

• Washer fluid• Power steering reservoir

• Defrost heater relays


Daimler Trucks

Technician Focused Improvements - Access

• Lower driver side access panel for chassis PDM’s


Daimler Trucks

Technician Focused Improvements – Misc.

• More reliable components should translate to fewer replacements

• Increased parts commonality means less parts for technician to maintain

• Bus can still be jacked up by front bumper


Daimler Trucks

Family Look

HDX EFX


Daimler Trucks

EFX Status


Gate 9/8 Status: Passed (May 9th)

Gate 7/6 Status: Passed

Scheduled SOP: Q1 2012

Project Budget approved.

Bus to be showcased at NAPT in October.

Estimated start of production 1Q2012

Pilot/Preseries

We’ll be soliciting orders within the next month

Will come with new sales codes – WebEx will be scheduled to assist in ordering process

Will come with $300 cost increase

Design Validation

Cooling passed.

FEA and fatigue analysis in progress.

Defrost testing planned for early October

6000 mile durability to begin mid-September at Bosch Proving Grounds.

Questions?

46

Thomas Built Buses Dealer Sales Meeting 2012

make every school bus better. thomas busoct 4, 2011 steve d goss sanjay kumar jim lannan

Documents

cummins slide

compromised slide

cummins fuel economy

acidic ph def slide

advanced egr egr

significant fuel economy

fluid def properties

better fuel economy