Cummins ISB Test Development Task Force Cummins Surveillance Panel Mark Sarlo, SwRI February 21, 2005

ISB Test Development Progress Labs and Engines Procedure, January 28, 2005 Draft issued Stand Visitation at SwRI, PE, and LZ Engine Build Workshop at SwRI Special Parts and Cam Measurement Update Procedure Update Stands Based on Stand Visitation Findings Move Forward to Matrix, dyed PC-10 Fuel

ISB Engine 5.9L ISB MY04, CPL This engine is certified at 2.0 g NOx/bhp-hr Fuel system Common Rail CPL8123 Low idle800 RPM (ECM 750 RPM) High idle3,000 RPM Rated300 2,600 RPM Torque peak600 1,600 RPM

ISB Engines at Labs San Antonio, Completed and San Antonio, Completed two and one Wickliffe, Completed Paulsboro, Preparing to Run Reference Oil Valvoline, Ashland, May Run Older Engine Configuration Afton, Richmond, Waiting on Engine, Waiting on Cell Space

ISB Procedure Highlights 350 Total Hours, (100-hr Stage A, 250-hr Cyclic Stage B) First 100 Hours at 1,600 RPM & 20 kg/hr, 107 kPa abs EBP, 110 C Oil Temp, 99 C Coolant Out, 68 C Int Man Retard Timing 14-16° to Generate Soot (use NGET) Soot Window of /- 0.25% at 100 Hours Charge Engine with 14.5kg Oil Total (Some into Filter) Two Flushes Before Test, One at EOT with Clean RAC & Pan External Oil Adder System, External Tube & Shell Oil Cooler Oil 25, 50, 75, & 100 Hr, 1,000 g Forced Add Return Timing to “Native Timing” for Final 250 hr Stage B Run Multi-step Valvetrain Wear Cycle for next 250 hr Oil 150, 200, 250, 300, & 350 hr with No Additional Oil Adds

ISB Procedure Highlights Coolant Out Temperature 99 Degrees C Engine Oil Sump Temperature 110 Degrees C Fuel Temperature 40 Degrees C Intake Manifold Air Temperature 68 Degrees C, 114mm Estimate 8,000 L Fuel per Test Use Cummins Complete PG Coolant 107 kPa Absolute Exhaust Back Pressure Set in Stage A, Open for Stage B??? Intake Air Restriction kPA Absolute Stage A, Barometric/Open for Stage B

Cummins ISB Stages A & B

ISB Test Numbering (Example) First Number is Lab’s Cell Number (64) Second Number is Run Number for that Cell (001) Third Number is Cummins Engine SN ( ) Fourth and Final Number is Hours on Engine After 80- hour Break-in Procedure

Cummins ISB, Typical Soot

Cummins ISB Soot, Stage A

Cummins ISB Soot, Stage B

Cummins ISB Cyclic Stage B

Cummins ISB Stage B Cycle

Special Parts CPD to Maintain and Etch Critical Parts Parts to be Etched in Sets and Sequentially, 1 Through 12 CPD to Maintain Inventory of Three New Engines New Engine Will Require 80 hr Break-in Engine Life Dependent on Lubricants Evaluated Estimate Up-to Ten Tests per Engine Block Points of Wear Include Camshaft & Tappet Bores in Block

Camshaft Wear Measurements Camshaft Lobes are Flat (Not Tapered) Determine Where Most Wear Occurs??? Use Adcole Gage to Measure Cam Supplier to Measure, Better System Investigating Alternate LZ Investigate Cam Shipping to Assure Safety Matrix-Related Cams Shipped to Warren Candidate Cams Directly to Cam Supplier

Camshaft Measurements Batch of Cams Pre-measured by Adcole CPD Maintains BOT Data

Special Parts Measurements for Matrix? Crosshead Weightloss (mg) Tappet Weightloss (mg) AFTER EnSolve® Cleaning Tappet Heightloss (mm) Tappet Stem OD wear (mm) Tappet Slider Surface Profile Wear in Two 90° Valve Adjusting Screw Weightloss (mg) Valve Rocker Lever Socket Weightloss (mg) Valve Rocker Shaft Weightloss (mg) Valve Push Rod Weighloss (mg)

Special Parts Measurements for Matrix? Camshaft Lobe Wear, Conventional (mm), Front, Middle, Rear Camshaft Lobe Wear, Adcole Method Camshaft Bearing Journal Wear, Conventional (mm) Camshaft Bearing Journal Wear, Adcole Method Tappet Bore Wear in Parent Block (mm) Cam Bore Wear in Parent Block (mm) Valve Lash Change (mm) Sludge Rating for Rocker Cover with and without Baffle Sludge Rating for Oil Pan

Summary Discrimination Proven with Mini-Matrix Update January 28, 2005 Draft Procedure Matrix Design Industry Participation, Stand Installation, Timing????

Mini-Matrix Data

Cummins ISB Pan Fitting Locations for External Oil Adder System