CumminsLight Truck

Clean Diesel Engine

September 2004

2

Technical Program Overview

• Partnership, Cummins and U.S. Department of Energy• Focus

– Development of technologies that will result in a product in thenear term

– Emissions~ U.S. Tier 2 6000-8500 lb GVW~ NOx = 0.07 g/mi; PM = 0.01 g/mi

– Fuel economy - 50 percent MPG improvement over 1997 gasoline powered vehicle it replaces

• Acknowledgment– Partnership funding from DOE– Vehicle and installation design assistance from Dodge Truck

Engineering– Engine Development Team at Cummins

3

US Passenger-Car & Light-Truck Market

0

10

20

30

40

50

60

70

80

84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 '00 '01 '02 '03

'04/7

% o

f Veh

icle

s So

ld

Cars

Light Trucks

54%

Source - Automotive News

4

V Family Goals and Status

Meets Goal

Partially Meets Goal; Plan in Place

V6 V8 V6 V8

Emissions

Noise, dBa72.7 db, Bare Engine

in Test Cell65.0 Interior, Cruise @ 65 mph, 1500 Pickup

Fuel Economy, MPG 22.1 Combined, Durango (+60%)

21.7 Combined, BR1500 (+60%)

Quality/Reliability

Rated Speed

Useful Life km(mi)

Performance 9.6 sec, 0-60 mph, 5940 lb PTW

8.8 sec, 0-60 mph, 6200 lb PTW

Displacement, Liter 4.2 5.6 4.2 5.6

Power, kW(hp) @ rpm 190 (250) @ 4000

260 (350) @ 4000

189(254) @ 3600 WG201(270) @ 3800 VNT

224 (300) @ 4000, Interim Target Met

Torque Peak, Nm(ft-lb) 455(335), 569(420) max.

597(440), 760(560) max.

569 (420) 623 (460)

Warm Up 49C in 10 min @ -30C

Focus in Phase 3

Serviceability

Cold Start 7.1 sec (1.2 sec Glow) @ -30C

Focus in Phase 3

Weight, kg(lb) 295 (650) 340 (750) 301 (663) 357 (788)

No Adjustments, Diesel Fuel Flter Added

4000 rpm (5000 max.) 4000 rpm (5000 max.)

Gasoline-Like (9-10 sec 0-60 mph)

Focus in Phase 3

< 20 sec. @ -30 C (-22F)

69 Hood Open, Equal to Gas

75 C(167 F) Coolant in 10 min. @ -30 C(-22 F)

Equal to Gasoline

B10 > 325,000 (200,000)

50 % Better than Gas

Focus in Phase 3

Target Actual (Status)Description

Tier 2 Bin 10 Interim Demonstrated, Tier 2 Bin 5 Final, Met in VehicleEPA Tier 2 & CA LEV II

Equal to Gas, <2 RPH First Year and <10 RPH Five Years

5

Phase 3 Engine withIntegrated Air Cleaner

6

Light Truck Diesel Subsystem Description

Subsystem Description Configuration 90° V Displacement 4.2 L V6 5.6 L V8 Bore and Stroke 94 X 100 mm Valvetrain and Drive Single overhead cam, chain-driven Valve System Four valves per cylinder with hydraulic lash adjustment Fuel System High-pressure common rail (HPCR) Control System Full electronic Emissions Control Modulated-cooled EGR plus 4-Way Catalyst (Tier 2, Bin 5)Aspiration Variable-Nozzle or Wastegated turbocharged Intercooling Vehicle mounted air-to-air Block Cast iron, thin-walled Head High temperature alloy aluminum NVH Control Ladderframe Accessories Common automotive V-8 gasoline Accessory Drive Single serpentine belt, self-adjusted

7

Prime-Path-System with 4-Way Catalyst System

Delta Pressure Sensor

O2Sensor

O2,Temperature

Sensors MY 07+, Tier 2 EPA & LEV II CAUnderfloor: PM Filter

N0x AdsorberHC & CO

Close-Coupled:Oxidation Catalyst

8

Catalyst Aging Cycle Description

700 C10 min

600 C5 min

Time

1 cycle

•Average Fuel Sulphur Level = 9.5 ppm, 20 mpg•Average Oil Sulphur Level = 4000 ppm, 25K miles/qt•3.6 ltr NOx adsorber•Sulphur Tolerance of 1 gm-S/ltr catalyst___________________________________________

•One DeSOx cycle per ~2200 miles (~110 gallon fuel consumed)___________________________________________

~ 68 DeSOx cycles prior to 150K emissions check

Temp

Lambda

9

Chassis Test Results - Bag ResultsV6 - 5000 lb. - 12.7 hp@50 mph

Test CO [g/mi]

CO2 [g/mi]

NOx [g/mi]

NMHC [g/mi]

FE [mpg]

PM [g/mi]

FTP-75 FUL limits

4.2 - 0.07 0.090 - 0.01

FTP-75 FTP-75

0.399 0.367 0.241

480.27491.67519.18

0.033 0.038 0.074

0.089 0.056 0.043

21.12 20.32 19.16

0.006 - -

bag 1 0.971 1.051 1.121

547.87583.44578.14

0.141 0.181 0.243

0.222 0.269 0.207

18.47 17.08 17.15

0.008 - -

bag 2 0.272 0.200 0.060

475.03475.27517.34

0.003 0.000 0.002

0.057 0.000 0.001

21.37 21.04 19.24

0.004 - -

bag 3 0.207 0.166 0.018

439.17453.40478.05

0.009 0.003 0.080

0.049 0.000 0.000

23.11 22.05 20.83

0.007 - -

•Start•1600 mi•Aged & Alt.

~150,000 mi5400 ft

10

V6 Emissions Progression

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0.1

0.2

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0.4

0.5

0.6

0.7

0.8

0.9

1

Sep-02 Dec-02 Mar-03 Jun-03 Oct-03 Jan-04 Apr-04 Aug-04 Nov-04

NO

x (g

/mi)

Steady State Engine Out

Vehicle Engine Out

Vehicle Tailpipe

5000 lb ETW•0.9 g/mi EOE NOx

5500 lb ETW•0.9 g/mi EOE NOx

Cat

alys

t

Cat

alys

t

Cat

alys

t

5000 lb ETW•VNT, 0.6 g/mi EOE NOx•Aged catalyst

11

Combustion Parameter Development

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1

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3

4

5

6

7

8

0 500 1000 1500 2000 2500 3000

Temperature (K)

Equi

vale

nce

Rat

io

fuel / airmixing

line

Igni

tion

Zone Soot

ProductionZone

NOxProduction Zone0

1

2

3

4

5

6

7

8

0 500 1000 1500 2000 2500 3000

Temperature (K)

Equi

vale

nce

Rat

io

fuel / airmixing

line

Igni

tion

Zone Soot

ProductionZone

NOxProduction Zone0

1

2

3

4

5

6

7

8

0 500 1000 1500 2000 2500 3000

Temperature (K)

Equi

vale

nce

Rat

io

fuel / airmixing

line

Igni

tion

Zone Soot

ProductionZone

NOxProduction Zone

FAF Control with Fast VG Valve

y = 0.9948x + 0.013R2 = 0.9707

0

2

4

6

8

10

12

14

16

0 2 4 6 8 10 12 14 16

FAF Cmd

Fres

h Ai

r Flo

w

Fresh_Air_Flow_Sensor Linear (Fresh_Air_Flow_Sensor)

Advanced Combustion

Precise Air Handling

Gen 3 PiezoFueling

Variable-Nozzle Turbo

12

Acceleration Test Results

3.97

8.60

5.334.54

9.62

6.004.17

8.84

0.00

5.00

10.00

15.00

0-100 ft 0-60 mph 50-70 mph

Tim

e, s

ec

5.7 l Gasoline @ 6000 lb5.6 l Diesel @ 6000 lb5.6 l Diesel Comp. @ 6200 lb

Gas = 345 hp @ 5400 rpmDiesel = 300 hp @ 4000 rpm

’04 ½- ton

13

Fuel Economy Results

13.7

17.9

15.313.1

17.1

14.6

20.3

25

22.1

19.8

24.6

21.7

0

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10

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25

30

35

City Hwy Comb City Hwy Comb

Test Condition

MPG

GasDiesel

Durango4.7 l Vs 4.2 l V6

49%44%

Ram 15005.7 l Vs 5.6 l V8

’04

½-t

on

14

Noise Test Results V8 in Ram 1500

66.6

49.7

72.176.3

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

Wendy's, Park @Idle

Interior, Park @Idle

Interior, 60 mph Open Hood, 3 ft at45 deg

Soun

d Pr

essu

re L

evel

, dB

a

’04

½-t

on

15

Comparison Phase 2 V6 vs Phase 3 V8

16

Base Engine Durability & Stability

• Cost Focused Areas

* Based on high-volume European diesel usage

17

Conclusions

• Light Truck Diesel Family continues to show promise• Customer features:

– Performance, comparable to Top Rated gasoline– Fuel economy, advantage 44-49% (improves CAFE)– Noise, approaching gasoline– Smoke and odor, eliminated

• Cost approached on a fundamental basis– Lower Engine-Out Emissions– High-Volume Gasoline Supply Base

• Final Tier 2 emissions, met in a complete vehicle system• There is a path to market for the Light Truck Diesel