1. APTA Bus Maintenance Webinar
Part 1
Introducing the 2013 Diesel Engine
Speaker: Tom Hodek, Cummins, Inc
Part 2
Long Beach Transit: Embracing CNG
Speaker: Rolando Cruz, LBT

2. APTA Maintenance Webinar - Introducing the 2013 Engine
Tom Hodek
January 24, 2013

3. Special Thanks

4. Discussion Topics Emissions Regulation 2013 Impact on Maintenance
Past and Present
How it has driven technology
2013 Impact on Maintenance
OBD / Fault Codes
Hardware Changes
Service Tools
Future Regulations
GHG Regs
Predicted Maintenance Changes

5. 2010: Near-Zero NOx and PM NOx / NOx+HC Particulate 2 4 6 8 10 12 19882 4 6 8 10 12
1988
1990
1995
2000
2005
2010
2015
2020
10.7g/HP-hr
6.0g/HP-hr
5.0g/HP-hr
4.0g/HP-hr
2.5g/HP-hr
1.2g/HP-hr*
0.2g/HP-hr
0.1
0.2
0.3
0.4
0.5
0.6
0.6g/HP-hr
0.25g/HP-hr
0.1g/HP-hr
0.01g/HP-hr
Urban Bus 0.05g/HP-hr

6. Emissions Reduction Impact
2000 =
1990
2000
2010
Nox (g/hp-hr) 11 4
0.2
PM (g/hp-hr)
0.59
0.05
0.01

7. Emissions Reduction Impact
2000
2013 (2010) =
(20)
1990
2000
2010
Nox (g/hp-hr) 11 4
0.2
PM (g/hp-hr)
0.59
0.05
0.01

8. Emissions Reduction Impact
1990 =
1990
2000
2010
Nox (g/hp-hr) 11 4
0.2
PM (g/hp-hr)
0.59
0.05
0.01

9. Emissions Reduction Impact
1990
2013 (2010) =
1990
2000
2010
Nox (g/hp-hr) 11 4
0.2
PM (g/hp-hr)
0.59
0.05
0.01
(55)

10. Evolution of Technology
NOx, PM
Selective Catalytic Reduction
Nitrogen Oxides and Particulate Matter
Over 90% Reduction of
Diesel Particulate Filter
Cooled Exhaust Gas Recirculation
Electronic Fuel Systems
Air to Air Aftercooling
1990
2000
2010
2020

11. Evolution of Technology
NOx, PM
CO2
and
Fuel
Efficiency
Selective Catalytic Reduction
Nitrogen Oxides and Particulate Matter
Over 90% Reduction of
Diesel Particulate Filter
Cooled Exhaust Gas Recirculation
Electronic Fuel Systems
Aftercooling
1990
2000
2010
2020

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

14. Cummins 2013 Engines Same NOx and PM emissions regulations as 2010
0.2g NOx and 0.01g PM
Same base engine and aftertreament as
New ECM
Integrated engine and aftertreatment controls
Intake air throttle for closed loop control (emissions)
OBD (On-Board Diagnostics) required – Diesel Only
New fault codes added to monitor emissions sytems

15. New ECM

16. Pictures of Air Intake and ECM
New Air Intake Throttle

17. What is OBD? On-Board Diagnostics
Monitors nearly every component that can affect the emissions control system
Tests emissions-related components and systems to detect malfunctions
Similar to passenger car systems or Cummins Turbodiesel in RAM Pick-up / Chassis Cab which have OBD-II systems for many years

18. Malfunction Indicator Lamp (MIL)
Located on the dash of the vehicle
It illuminates to indicate an OBD related fault
Simplifies diagnostic and repair procedures for the technician and servicing location

19. On-Board Diagnostics (OBD)
Aftertreatment System Monitoring
ECM Monitoring
Engine System Monitoring
Service Tools
MIL

20. What Does OBD Mean For The Transit Industry?
Better monitoring of emissions systems
Increased accuracy in determining the root cause of emissions-related faults
Provides early warning of malfunctions

21. Maintenance Changes for 2013
Fuel Filter change intervals (now at every oil change)
NanoNet fuel filter medium
Inspection intervals reduced
Radiator cap and SCA levels (20K to 15K miles)
Engine drive belts & tensioner (40K to 30K miles)
Air compressor discharge line (80K to 60K miles)
Aftertreatment servicing
Frequent regeneration faults
OEM Coolant Recover Tanks
Add Coolant to recovery tank, not top tank
OBD Fault Codes
New fault codes all added for emissions compliance
Cummins Insite / Generic Scan Tool

22. Service Tools
INSITE – Maintains ability to perform Cummins specific special tests whereas a generic scan tool cannot.
QSOL (QuickServe OnLine)
EDS – Next Generation Diagnostic Tool product offered through Cummins certified repair locations.
OBD connector style will be the same 9-pin connector used previously

23. Evolution of Technology
NOx, PM
CO2
and
Fuel
Efficiency
Selective Catalytic Reduction
Nitrogen Oxides and Particulate Matter
Over 90% Reduction of
Diesel Particulate Filter
Cooled Exhaust Gas Recirculation
Electronic Fuel Systems
Aftercooling
1990
2000
2010
2020

24. Future Regulations 2014 GHG Standards
CO2 Limits: Reduce by 3% in 2014 to 9% total in 2017 over a 2010 industry baseline
N2O and CH4 Limits (already met in 2010)
Cummins EPA 2013 compliant engines meet 2014 Greenhouse Gas and Fuel Efficiency standards
OEM (TVM) needs to use tires that are certified for compliance with GHG reduction (rolling resistance)

25. Hybrid Engine Regulations
Cummins will offer Hybrid engines that meet both EPA and ARB 2013 certification requirements.
Hybrid ratings will be distinct from conventional (non-Hybrid) ratings
Hybrid ratings with Engine Start Stop (ESS) capability will be distinct from non ESS Hybrid ratings and will be limited to one ISB Transit Bus rating. (First availability: July 2013)

26. Future Development Vehicle Manufacturer Integration
All subsystems
Cooling System Improvements
Fuel Economy
GHG Compliance in 2014 and 2017
Aftertreatment
Improved Efficiency
Future Maintenance Requirements
None at this time

27. Thank You

28. Long Beach Transit Embracing CNG
APTA Webinar
January 24, 2013 28

29. Agenda Background Why CNG? Procurement Training SCRTTC
CNG Station / Site Modification
CNG Buses
Training
SCRTTC

30. LBT Mission
Long Beach Transit is in business to provide public transportation services that enhance and improve the quality of life for the people in our community.
We serve Long Beach, along with 11 other cities – 98 square miles
29 million ridership

31. Quality of Life
Sustainability – drives our decision to clean up emissions on our vehicles
Diesel Coaches – all purchases prior to 2003
Installed particulate traps on diesel buses in 2001
Early adopter of ultra-low sulfur diesel
2003 made a decision to go gas hybrid
Procured 89 gasoline hybrid electric buses to date
Staff and operations vehicles are actively being replaced with hybrids
2010 – completed alternative fuel study with WVU – essence maintain diverse fuel choice

32. CNG Plans LBT planned on CNG for 2015
CNG economically good vs gas hybrid
Lower Operating Costs w/ tax credit
Infrastructure costs - break even point at one property for 40 coaches & other 70
ISE bankruptcy in late 2010
CNG purchases moved to 2012
Must build a CNG station within one year
Modify both facilities to accommodate CNG
Procure 64 buses with CNG engines

33. Fleet Makeup Revenue Fleet Other Services Support Vehicles
171 – 40’ New Flyer buses (89 gasoline electric hybrid)
13 – 60’ New Flyer articulated buses
64 CNG – 40’ Gillig BRT
10 Electric buses in 2014
Other Services
17 Dial-A-Lift vans (Paratransit)
4 boats (2 AquaBus & 2 AquaLink)
1 Charter (Prevost)
Support Vehicles
31 service veh for supervisor, staff & operators
25 maintenance service vehicles
TOTAL of 326 VEHICLES
4 Propulsion Systems (Diesel, Gasoline Hybrid, CNG & All-Electric)

34. CNG Station, Infrastructure Modification & Buses
Project Plan
Our challenge began with the teams education in natural gas fuel. We needed to talk to the people in the know about CNG.. We started with existing users, vendors and multiple stakeholders using CNG, and our Governing Agencies regulating its safe use. 34

35. CNG Project Goals
Provide CNG fueling station able to fuel 77 – 95 coaches
Upgrade infrastructure to accommodate repairs in entire shop & fuel island
Prepare utilities for CNG (gas & electricity)
Buy 64 CNG buses
Get LBT transitioned to CNG
Environmental understanding - ESMS
The goals / project charter and budget were drafted to:
Provide a CNG station to service up to 95 coaches
Upgrade all of LJ maintenance facility and any parts of AA that had unique service
Prepare for our gas & electricity requirements
(delete above)
Our CNG team identified our basic project goals:
Provide a CNG compression station to service up to 95 coaches each night after completion of service. The limited bus service time window resulted in our selection of a bus fast-fill method versus a slow fill method.
Upgrade all of LJ maintenance facility and select portions of AMF to safely accommodate lighter-than –air fuels within the buildings.
Prepare utility connections for natural gas and electrical power usage far beyond the abilities of our current service connections.
And of course start drafting a transition plan for CNG 35

36. Project Constraints
Goal 1 year – anticipating delivery of new CNG coaches
Budget for station was tight – need to keep within $6.2 million
Heavy workload on facility team
Limited Staff Experience for CNG
Limited Staff Time for Project
Need City approval & cooperation (including LB Fire Department) – avoid EIR if at all possible
Our constraints were a little tougher – as always TIME and MONEY.
We had a tight timeline - 6/30/12 only 15 months. We knew that upon bus delivery, a fueling location and service location would be mandatory.
A tight budget, projected at $6.2 million
Overworked Staff with limited direct CNG experience – equates to slow project development time.
The key regulatory stakeholders such as our City Planning & Building, and the Fire Department needed to provide regulatory approval of the initial design assumptions and concepts, before proceeding with detail plans.

37. CNG Station Contract Awarded
4 qualified proposals received ranging from $4.5 to $6.18 million
Contract Awarded to Amtek Construction, Lowest bid at $4.5 million
Proposed Angi Energy Systems
Compressors – five (500-scfm/250-hp)
Gas Dryer - accommodate 3000 scfm
Two (2) Buffer Storage paks
2 CNG fast-fill Dispensers & 1 slow
Modify all of LJ facility (12 bays) & 3 bays at AA facility
So four (4) Proposals came in and boy did they vary in pricing. The total price ranged from $4.5 million to $6.18 million. We ranked the proposals and conducted interviews with the top two scoring firms. In the end, the Amtek Construction (proposing Angi energy systems equipment) was deemed as offering the best value and presented the lowest cost of $4.5 million. With all other development costs, we were able to build our entire CNG project for the original projected budget of $6.2 million.
3-4 req for typical fueling rate of 1800 scfm
1 compressor off-line for service or backup
5th shown as bid deduct budget flexibility
Dual Edison meters to reconcile cost of compression

38. Maintenance Impact Station
Need Daily inspections & scheduled PM’s
LBT chose to contract out
Amtek – 1 year maintenance agreement
Clean Energy – doing daily & oversight
Going out to bid to award long-term contract, still need some facility training
Need to train all employees on Safety & Maintenance on fueling

39. CNG Coach Purchases
Piggy Back - contract with Gillig for 64 coaches (after full evaluation)
Cummins Engine – ISL G - 280
ZF Transmission – Eco Life 6AP 1400B
CNG Tanks & Fueling System
Gas Detection w/ Fire suppression

40. Maintenance Impact Buses
Fluids resulting from CNG / ISLG:
A low ash engine oil
A premium long life coolant
Material Review & order
Preventative Maintenance Impact
Gas detectors & system health
Inspection of CNG components, valves, piping, leak detection, filter draining & replace
CNG tank inspection at 3 yrs or 36,000 miles by a “certified” inspector, required training and CSA test for cert. LBT will do once per year.
Others in part because of the opportunity or newer components:
Longer life synthetic axle oil
Synthetic fluid for the new model ZF, Ecolife

41. CNG Training
Project Plan 41

42. Training Training Needs No one Stop Shopping
CNG Station / Site Safety
CNG Tanks / Safety
CNG Engine
No one Stop Shopping
LBT staff looked at all options
Amtek / ANGI
Natl Gas Vehicle Institute (NGVI)
Gillig, Cummins, Amerex
SCRTTC

43. CNG Site Awareness & Safety
Facility - ANGI (Fuel Station)
Utility - CNG Safety & Fueling
Maintenance - CNG Safety / Methane detection
Staff – CNG Awareness
612 Total Hours

44. Bus Safety / Tank Certification
Gillig CNG Safety, PM, Air systems
Amerex Fire & Methane Detection
NGVI Safety and Tank inspection
Tank Inspection – SCRTTC via LB City College
1,224 Total Hours

45. CNG Engine Cummins – 2 days SCRTTC Course
Crash course - Cradle to Grave
Taught by skilled technician
SCRTTC Course
4 courses – total of 6 days
Spread out over time and can do at a slower pace with standardized course & trained instructor
LBT limited the amount of mechanics in courses intends to expand

46. SCRTTC Southern California Regional Transit Training Consortium
The Future in Training

47. The SCRTTC Purpose
To provide a training resource network, comprised of public and private organizations, focused on the development and employment of the transit industry’s workforce that is proficient in the standards, practices and procedures for incumbent and new workers.

48. The SCRTTC Overview
California Corporation and 501 c (3) Non-Profit – formed in 2005
Partnership of 48 members consisting of Transit Systems, Community Colleges, Affiliate Members and Private Partners
Provide research to demonstrate feasibility of a new transit workforce development ‘Learning Model’
Develop and deliver Transit Training providing the workforce knowledge of ITS standards, practices, and procedures.
(early start in 2003)

49. The SCRTTC Goals
Develop a new “Learning Model” to increase the professional and technical competency of the Southern California public transit workforce
Assure that this new “Learning Model” includes the elements of Intelligent Transportation Systems (ITS)
Develop industry driven, competency based courses that meet present and future needs
Deliver standard courses to mechanics throughout the region via colleges

50. SCRTTC Transit Members
Southern CA Members
Antelope Valley Transit Authority
Arcadia Transit
Beach Cities Transit
Claremont Dial-a-ride / Pomona Valley Transportation Authority
Commerce Municipal Bus Lines
Culver City Municipal Bus Lines
Foothill Transit
Gardena Municipal Bus Lines
Gold Coast Transit
LA DOT
La Mirada Transit
LA METRO
Long Beach Transit
Montebello Bus Lines
Norwalk Transit
OCTA
OMNITRANS
Santa Clarita
Santa Monica Big Blue Bus (BBB)
Torrance Transit Systems
Sunline Transit
Other Transit Agencies
Fresno Area Express
Monterey-Salinas Transit District
Roaring Forks Transit Authority
San Joaquin RTD

51. SCRTTC College & Partners
College Members
Cerritos College
Citrus College
College of the Desert
Colorado Mountain College
Cypress College
El Camino College
Golden West College
Kern Community College District
LA Trade Tech College
Long Beach City College
Rio Hondo College
Saddleback College
San Diego Miramar College
Santa Ana College
Affiliate Members & Partners
American Public Transportation Association
Advanced Transportation Technology and Energy Initiative (ATTEi)
California State University - LB
Colorado Transit Association
UC, San Diego
USC - Mettrans
ATech Training Inc., Walton, KY
Proterra, Golden CO
Clean Energy
Complete Coach Works
New Flyer of America

52. SCRTTC Training Hours Training Delivered - Life To Date
Total Hours of training delivered: 50,184
Total Participants trained: 3,504
Cummins 8.9 Series (Level I,  Insite,  Level II):
Total Hours of training delivered: 4,816
Total Participants trained to date: 342
CNG 1-day Safety:
Total Hours of training delivered: 96
Total Participants trained to date: 12
CNG Cylinder tank inspection:
Total Hours of training delivered: 576
Total Participants trained: 36

53. CNG Training CNG Transit Vehicle Safety Training - #SC-CG-4100-I
Basic fuel characteristics regarding flammability
Basic fuel characteristics regarding pressure
Basic pressure system design
Safety related pressure system components
Basic cylinder care & damage
Proper depressurization techniques
Pressure system component servicing
High pressure fitting servicing
Leak detection techniques
Cummins INSITE Diagnostic Software - #SC-EN-1712-I
Select, add and connect proper adapters to a bus
Access, custom group, and verify parameters
Access, define, research, and clear fault codes
Produce snapshots, data logging, and Graphing
Look up engine derate, enabling criteria and other troubleshooting technique information
Navigate the Electronic service tools for Cummins
Cummins ISL-G Engine Mgmt System Level I - #SC-EN-1710-I
Define Mass Air Flow Fuel Mgmt Systems
Identify, locate & test parameters with:
DVOM
Temperature Sensors
a Pressure Sensors
Position Sensors
Voltage Producing Sensors
Mass Gas & Air Flow Sensors
Use INSITE to verify parameters
Cummins ISL-G Engine Mgmt System Level II - #SC-EN-1711-I
Diagnose faults using INSITE for:
Ignition Systems
Pressure Sensors

54. The Difference in Courses
Courses developed with the learning model
College collaborates with transit agency (& vendors) to develop curriculum
Standard set of materials created & approved
Beta Testing of course with Subject Matter Experts – changes made to coursework
Train-the-Trainer delivered to ensure quality of trainers
Courses refreshed every 3 years

55. Transit’s benefit in use of SCRTTC
Standardized course
Manage Technicians Time
Less time off floor – can spread out (2–3 at a time)
New Technicians come in, can get training
Sharing of Resources –
Reduced cost to each agency
Multiple agencies come to course
Technicians get to Network
Colleges are familiar with transit agencies /
Great recruitment for future
Students can learn skills required for transit

56. The Future of Training
Continued course development of advanced technology
More Partnerships with Vendor
Vendor use of SCRTTC to develop course will provide standardized, transit approved courses
Standard material (pre/post test, objectives, student material/exercises, instructor material)
Sharing of Material & TTT with non-regional members - expansion

57. For More Information http://scrttc.com/
History & info of SCRTTC at finger tips
Ability to look at any class curriculum
On-line registration for one or group
Rolando Cruz