1. Make Every School Bus Better.
Thomas Bus Oct 4, 2011
Steve D Goss Sanjay Kumar Jim Lannan

2. Agenda Update on successes IC Bus ‘Fluid’ Economy Claims
Cummins Fuel Economy
How to sell Cummins

3. School Bus Industry Data
Industry data suggests a 5% gain in Cummins market share (50% to 55%)
Recently gained business with largest bus customer

4. 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
‘Fluid Economy’ also ignores the price differential
Avg. Diesel Price
$3.80
Avg. Bulk DEF Price
$2.85

5. 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

6. 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

7. ‘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

8. Cummins Fuel Economy ‘Others Test. We Deliver’
Cummins and Thomas Bus both currently testing

9. ISB Fuel Economy Tops DTNA Testing
Freightliner M2 106
with Cummins ISB
(EPA 10)
Vs.
International Durastar 4300
with
MaxxForce DT (EPA10)
Result
8.5% Better Fuel
Economy
2 Regens for ISB Vs 10 for MaxxForce DT in the hour test period

10. 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

11. In Cylinder NOx Control Challenges
5-9% disadvantage
Combustion efficiency degradation:
Higher engine pumping losses
Increased intake & exhaust manifold pressures
Increased Particulate Filter regenerations
Fuel Economy Significantly Compromised

12. In Cylinder NOx Control Challenges
Increased Risk of EGR Condensation
Higher EGR flow produces excessive acidic condensation
Power cylinder corrosion
Rapid deterioration of lube oil
Reliability and durability compromised

13. In Cylinder NOx Control Challenges
Significant Increase in Heat Rejection
20% increase
Higher EGR flow:
Multiple EGR coolers on & off engine
Larger vehicle cooling package
Major redesign of radiator / Charge Air Cooler / Fan systems

14. In Cylinder NOx Control Challenges
Complex System Integration
Higher EGR flow
Air handling system
Vehicle cooling system

15. In Cylinder NOx Control Challenges
Higher EGR Flow
Throttle Response
Driver Satisfaction Significantly Compromised

16. In Cylinder NOx Control Challenges
Deterioration of 50 – 100 hp for same displacement
Higher EGR flow & EGR controls compromises engine performance
Power Density and Torque Limitations

17. Bus Owners Have Two Choices for 2010
Advanced EGR
Intercooler
Clean Air
DOC
DPF
Radiator
Higher heat rejection:
Larger Radiator
Larger Charge air cooler
EGR + SCR After-Treatment System Setup
Tank
Catalyst
Doser
AMOX Cat
DOC
DPF

18. 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
Acidic pH
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
DEF

20. DEF - Myths & Facts
Navistar’s claim of ammonia level being close to 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

21. Cummins ISB6.7 vs Navistar MaxxForce 7 Competitive Comparison

22. Cummins ISB6.7 vs. MaxxForce 7
Feature
Cummins Advantage
Displacement
6.7L
6.4L -
Configuration
Inline 6
V-8
Fewer parts /
better reliability
Horsepower HP HP
Better power
density
Torque
lb-ft
lb-ft
Aspiration
One - variable geometry turbo
(2) dual stage
turbos
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

23. Competitive Comparison Summary
Feature
Cummins ISB6.7
Advantage
MaxxForce 7
Complexity
Single 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

24. 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

25. Cummins Diesel Power

26. 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

27. ISB6.7 & ISC8.3 Customer Benefits
Best-in-Class Fuel Economy
Improved Reliability
Minimal Installation Impact
Stronger Performance
Increased Power Density

28. Cummins Natural Gas Power

29. 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)

30. 2010 ISL G Natural Gas Stoichiometric Combustion Cooled EGR
Same rated speed as ISL9 diesel
30% more torque at idle
5% better fuel economy
Three Way Catalyst Aftertreatment
Passive device
Packaged as a muffler
Maintenance-Free

31. Aftertreatment System
Integrating Critical Subsystems
Filtration and
Diesel Exhaust Fluid
Electronic Controls
Aftertreatment System
Combustion
Technology
Turbochargers
Fuel Systems

32. PowerSpec www.powerspec.cummins.com Software Application
Provide gearing recommendation
Customize engine ‘specs’
Collect valuable trip information
Free to download and use

33. 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: ) includes all necessary parts to connect the vehicle to a laptop

34. 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

36. Saf-T-Liner EFX

37. Common Parts with HDX means faster design cycle
Sub-system ID (estimated number of parts to be eliminated ~100)
Destination Sign
(20)
Front Roof Cap
(6)
#2 Hood
(2)
Clearance/Marker Lights
(6)
Windshield
(3)
Wipers
(15)
Header Height/Drip Rail
(4)
“A” Mirrors
(8)
Hazard Lights
(4)
“B” Mirrors
(8)
Bumper
(10)
Headlight & Bezel
(4)
Walk Gate
(8)
Thomas Built Buses Standard Template.ppt

38. Driver Focused Improvements - Storage
Added driver’s storage to right side dash
Can be used for safety equipment storage or for personal items
Thomas Built Buses Standard Template.ppt

39. Driver Focused Improvements - Visibility
Improved visibility
HDX windshield
Larger driver’s side window
Argosy headlights
Running lights standard
Thomas Built Buses Standard Template.ppt

40. Driver Focused Improvements - Visibility
Improved defrost capability
Thomas Built Buses Standard Template.ppt

41. 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
Thomas Built Buses Standard Template.ppt

42. Technician Focused Improvements - Access
Lower driver side access panel for chassis PDM’s
Thomas Built Buses Standard Template.ppt

43. 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
Thomas Built Buses Standard Template.ppt

44. Family Look
HDX
EFX
Thomas Built Buses Standard Template.ppt

45. 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.
Thomas Built Buses Standard Template.ppt

46. Questions?
Thomas Built Buses Dealer Sales Meeting 2012