Application

Engineering
Bulletin
Subject This AEB is for the following applications:

L Gas Plus Technical Package

Date February, 2004 Page 1 of 9 AEB Number 10.104

Engine Models included: L Gas Plus

INTRODUCTION

Cummins Westport is introducing the next new spark ignited natural gas engine, the L Gas Plus. The L Gas
Plus is a 6 cylinder engine with an 8.9 liter displacement, and the latest evolution of our full authority
electronically controlled fuel system. It incorporates many of the ISL03 diesel engine enhancements and utilizes
variable geometry turbo-charging for improved response and increased power and torque.

The Electronic Control Module (ECM), CM556, is similar to the one used on the C Gas Plus engine. Like the C
Gas Plus engine, the following features are available in the L Gas Plus: communication via the J1587 and J1939
data-link, wide range fuel capability, engine diagnostics, integrated engine and speed controls, knock detection,
exhaust oxygen sensing, intake air humidity sensing, engine protection and adaptive learn technology.

For detailed information on Electrical and Electronics, see Application Engineering Bulletins 15.35, 15.36, 15.37,
and 15.38.

The initial rating available for the L Gas Plus will be 320 horsepower. The ratings will meet 1.5 gm NOx+NMHC
and .01 gm PM on the 2004 EPA/CARB cycle tests. A catalyst is required for all ratings. Subsequent lower
ratings will be released post launch.

PURPOSE

The purpose of this technical package is to communicate information about features of the hardware and
software of the L Gas Plus, as well as the product introduction plan.

ENGINE PERFORMANCE DATA

Power Output:

The power output for the initial L Gas Plus engine will as follows:

Power Output Torque Peak

320 HP @ 2300 RPM 1000 lb-ft @ 1400 RPM

AUTHOR: David King

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ENGINE VIEWS

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ENGINE ARCHITECTURE

Air Intake System

A 90-degree elbow air intake connection with a 4” hose connection will be provided as the intake connection on
the engine for the cooled charge air. The engine can be specified with this oriented vertical or horizontal. This
is the same as the C Gas Plus.

An intake elbow at the turbocharger inlet will be supplied with the engine. This elbow will contain a compressor
inlet pressure sensor and a humidity sensor as well as the Closed Crankcase ventilation return. This intake
elbow must be used with the engine. It may be rotated by the OEM for installation flexibility.

Alternator Mounting

The L Gas Plus will have some of the same option offering as the 2003 ISL.

Compressed Air System

Cummins single cylinder 18.7 CFM and twin cylinder 30.4 CFM air compressors will be available on the L Gas
Plus. Both air compressors have the water plumbing ports on the top side, the air inlet/outlet connections
located on the back side, and the air un-loader connection located on the outboard side of the compressor. A
hard line coolant plumbing (CC) option is available for all compressors and a hard line air inlet plumbing (CI)
option to the engine cylinder head is available for the turbocharged compressors. The HD air compressors are
no longer offered. Non-Cummins air compressors will not be offered, and OEM-supplied air compressors will not
be allowed, due to the air requirements of the turbo actuator.

The L Gas Plus requires a pressure-protected vehicle air supply to the VG turbo. The airflow requirement is 1
liter/ minute of air under normal operating conditions. During periods of rapidly changing load on the engine, the
turbocharger actuator will require 75 liters/minute for a duration of 0.2 seconds. The Herion air valve controls the
turbocharger actuator and is mounted atop the engine. The OEM must plumb air to this valve and connect to an
M12 straight thread o-ring port. The allowable water content of the air supplied to the Herion valve must have a
maximum dew point of 40 C (104F). The maximum particle size in the inlet air is 160 microns. Maximum air
pressure supplied to the Herion is 184 psi. (12.5 bar). An air dryer is mandatory in order to meet the air quality
requirements of the VG turbo actuator.

Compressor thru-torque will be 105 lb-ft for turbocharged applications and 125 lb-ft for naturally aspirated
applications. An 11-tooth spline (SAE19-4) will be used on 105 lb-ft thru-torque compressors. A 13-tooth spline
will be used on 125 lb-ft thru-torque compressors. Compressor rear flanges will be SAE A (82-2) in both cases.

Cooling System

The cooling system has been changed versus the current C Gas Plus engine. The coolant path has changed
such that the coolant flows around the cylinder liners first then through the cylinder head. This changes the
pressure and temperature of the coolant manifold ports. Coolant flow on the L Gas Plus will be comparable to
the flow on the 2003 ISL engines. Water inlet and water outlet options will carry over from the 2003 ISL engine
as will torque converter bypass options and block heater options.

With the higher output of the L Gas Plus, the heat rejection to coolant will be higher for this engine than the C
Gas Plus. The charge air heat rejection will also increase. See the engine data sheet for details.

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Another significant improvement is that the requirement for a mandatory corrosion resistor has been dropped.
The customer-specified option will be available as a chassis-mounted or engine-mounted option. OEM’s may
also install their own corrosion filter provided it meets the Cummins specifications.

It is important to that fully formulated antifreeze or coolant with a pre-charge of supplemental coolant additive
(SCA) be used. See the Operation and Maintenance (O&M) Manual for an explanation of these terms.

The VG turbo has a water-cooled bearing housing. A continuously deaerating line must be installed by the OEM
from the VG turbo bearing housing to the radiator top tank. The top front of the cylinder head must also be
vented to the radiator top tank. Two connection sizes will be offered: a 3/8” push-on hose connection, and a
7/16” x 45 degree flare fitting. In addition, the OEM must provide a coolant level sensor in the top tank. A 10
psi. minimum pressure cap is required.

Cylinder Block

A new cylinder block has been released for the L Gas Plus engine that is similar to the 2003 ISL diesel engine
rather than the C Gas Plus block. There are several changes incorporated on the new block that may affect
installations as compared to the C Gas Plus. Review the installation drawing for specific details.

Cylinder Head

The cylinder head will be the two valve per cylinder head that is used on the C Gas plus.

The valve train and overhead are similar to C Gas Plus but with wider slider tappets.

Electronic System

The L Gas Plus will utilize the CM556 engine control module (ECM) as is used on the C Gas Plus. The CM556
is mounted on the fuel system side of the block along with the ignition control module. The L Gas Plus will use a
new Ignition system that has expanded capabilities over that of the C Gas Plus. This new ignition system will
have onboard diagnostic capabilities and will have unique wiring from that of the C Gas Plus. The OEM
electronic interface to the L Gas Plus will remain the same as the C Gas Plus.

The power supply for the engine electronics will need to be 12 Volt just like C Gas Plus. Using a 24 Volt system
will require a voltage converter. The L Gas Plus has a maximum key on current of 40 amps at 12V.

The electronic system includes the following sensors (partial list) located on the engine for monitoring the engine
system parameters:

• Coolant temperature sensor located on the front exhaust side of the cylinder block immediately forward of
the lube oil cooler.

• Oil pressure sensor located on the fuel system side of the block.

• Intake manifold temperature and pressure sensors located in the intake/mixer assembly.

• Engine position sensor located on the gear housing.

• Engine speed sensor located in the cylinder block.

• Fuel inlet pressure sensor located at the OEM fuel inlet connection.

• Turbocharger compressor inlet pressure and humidity located at the compressor inlet connection.

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The following electronic tools will continue to be available: Insite and QuickCheck.

J1587 and J1939 datalinks will be available.

For additional details about the electronic control system consult the CM556 Electronic Subsystem Technical
Packages and the Automotive Installation Requirements-L Gas Plus Electronic Subsystem.

Engine Mounting

The L Gas Plus will have some of the same option offering as the 2003 ISL.

Engine Specification Changes

The L Gas Plus engine will be released with a new technical configuration number D883001BX03.

Engine Starting Aids

Some of the same oil pan immersion heater and coolant heater option as 2003 ISL will be made available on the
L Gas Plus.

Exhaust System

The exhaust manifold is new for the L Gas Plus, and will position the turbo centerline in a unique position due to
the larger turbo housing size. This will be similar to the 2003 ISL mid-mount rear out position.

Catalysts will be required to meet 2004 EPA/CARB certification requirements for all ratings on the L Gas Plus.
Refer to the data sheet for the particular rating to get the proper catalyst.

The L Gas Plus will incorporate a Holset HY40V pneumatically actuated, variable-geometry (VG), turbocharger.

Cummins will not supply an exhaust adapter that houses the exhaust backpressure sensing port and the heated
exhaust oxygen sensor (HOS) as is provided on the C Gas Plus. For the L Gas Plus the OEM will have the
responsibility of installing the Cummins supplied exhaust oxygen sensor in their exhaust piping and supplying an
exhaust backpressure sensing line from that location to a connection on the engine cylinder head. The OEM
will need to ensure the installation of these components is in accordance with the Cummins Installation
Requirements specified for the L gas Plus.

Exhaust brakes will not be offered and cannot to be used on the L Gas Plus.

Flywheel

The L Gas Plus will have some of the same option offering as the 2003 ISL.

Flywheel Housing

The L Gas Plus will have some of the same option offering as the 2003 ISL.

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Front Belt Drive

The L Gas Plus will have some similar options offered as the 2003 ISL.

Fuel System

The natural gas fuel system used on the L Gas Plus will be similar to that used on the C Gas Plus with the most
noticeable change being the L Gas Plus will utilize boost referenced final fuel pressure regulation.

The L Gas Plus will have wide range fuel capability like the C Gas Plus. The fuel specification for use with the L
Gas Plus engine is described in AEB 79.02.

Gear Housing & Cover

A new gear housing has been released for the L Gas Plus engine that is similar to one of the gear housings
released on the 2003 ISL. It is the low-mount accessory drive housing that accommodates the air compressor
mounting. The engine position sensor was retained in the gear housing while the engine speed sensor was
relocated to the cylinder block.

Installation Drawing

A preliminary installation diagram is available for the L Gas Plus. The drawing number is 3170584. CAD
models are available for a variety of options in Pro/Engineer, Step, Unigraphics, and Catia formats.

Lubrication System

The lube pump flow capacity on the L Gas Plus engine is comparable to that on the 2003 ISL. The amount of
engine oil flow that can be used for external accessories, not including air compressor and REPTO, will be 2.0
gpm. This is the same as the 2003 ISL capacity.
The L Gas Plus will utilize the Fleetguard LF9009 combo filter. The LF3000 will fit on the L Gas Plus filter head
but should not be used. The filter head design has changed to utilize the stacked bypass filtering capability of
the LF9009.

Oil fill locations on the front of the gear cover, on the exhaust side, and on the fuel system side of the cylinder
block, and in the valve cover are available.

Most dipstick arrangements on the L Gas Plus engine will be carried over from the 2003 ISL.

Most oil pans will on the L Gas Plus will be carried over from the 2003 ISL.

Centinel will not be offered.

Noise

Natural gas engines provide a distinct noise signature different than diesel engines. These engines are supplied
with a gear driven air compressor. This variation of noise is normal and will not result in durability problems with
the gear train or air compressor.

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Refrigerant Compressor Mountings

The L Gas Plus will have a similar option offering as the 2003 ISL except less the left side cylinder head mount
option. This is not compatible with the ignition system

Starters

The L Gas Plus will have some of the same option offering as the 2003 ISL.

Vibration Damper

The L Gas Plus will have some of the same option offering as the 2003 ISL.

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Change Log

March 2003 Creation All

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