Application

Engineering
Bulletin
Subject This AEB is for the following applications:
Auto and Bus Installation
Requirements – CWI Spark Ignited, Automotive Industrial Marine
Lean Burn Gas Engines
G-Drive Genset

Filtration Emissions Solution

Date: July 1,2009 AEB Number 21.48

Engine Models included: ISB5.9G, B Gas Plus, B Gas International (BGI), C Gas Plus and B LPG Plus

Author: Rick Mason Approver: per Procedure 9183OPS-04-10-01 Page 1 of 10

This AEB supersedes AEB 21.48 published August 23, 2007.

This AEB transmits the Automotive and Bus Installation Requirements for the Cummins Westport (CWI)
ISB5.9G, B Gas Plus, B Gas International (BGI), C Gas Plus and B LPG Plus spark ignited, gas engines.
These engines use lean burn combustion technology.

Exhaust Temperature Drop Requirements are included for BS IV, Euro 4, Euro5 and EEV ratings, see page 4.

Installations of B LPG Plus engines in vehicles certified to Large Non-road Spark-Ignited Certified Regulations
must follow the additional, emissions specific instructions on page 5.

This document does not apply for L Gas Plus and ISL G engines. Refer to the separate installation
requirements documents for those products, use AEB 21.58 for L Gas Plus and AEB 21.75 for ISL G.

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INSTALLATION REQUIREMENTS

In order to obtain Cummins concurrence, to an engine installation, the following requirements must be met:

• A minimum of 6 inches of clearance above the valve cover is required for spark plug and ignition coil
removal.

• The Cummins low-pressure fuel filter must be easily accessible for draining. The drain must not be above
any electrical components, or the exhaust manifold.

• The Cummins Westport provided exhaust adapter must be used.

• The exhaust manifold, turbocharger, catalyst, and heated oxygen sensor (HOS), must not be wrapped or
insulated with any material.

• Internal Grommet Temperature of the HOS must not exceed 200 °C (390 °F) and

• The orientation of the HOS sensor must be +/- 80 from vertical on the top side of the exhaust adapter.

• The complete exhaust system must meet the backpressure specifications shown on datsheet.

• All except BPLPG. Gas must be supplied to the engine fuel inlet connection within the maximum and
minimum pressures and temperatures listed on the engine datasheet under all engine operating conditions.
Gas inlet pressure should be steady within +/-69 kPa (+/-10 psi variation) under transient speed and load
conditions.
• For B LPG Plus engines – LPG must be supplied to the engine at a steady pressure (+/- 5 psi) under all
conditions (temperatures and fuel flow rates) and meet the fuel pressure requirments oulined on the engine
data sheet.

• For cold weather enviroment operation of B LPG Plus engines, a pressure assist vehicle fuel system is
required to achieve the fuel pressure requirements.

• Fuel Supply System meets appropriate Cummins installation requirments per AEB 21.17 for LNG, AEB
21.25 for CNG or AEB 21.53 for LPG as appropriate.

• An electric fuel shut-off solenoid, controlled by the ignition switch, is installed as close to the tanks as
possible (This is an OEM supplied component).

• For B LPG Plus, the coolant ports at the rear of the cylinder head must not be used for OEM coolant supply.
Coolant for accessories such as cab heaters must use the ports made available at the front of the head near
#1 cylinder near the thermostat housing.

• Cooling system fan controls must have direct coolant temperature and intake manifold temperature sensing
(Refer to AEB 21.38 for values) or uses ECM fan control.
• Surface temperature at the ECM must not exceed 104°C (220 °F).
• If the engine is equipped with Closed Crankcase Ventilation (CCV), the system must be mounted and
plumbed correctly per AEB 48.02.
• Installations of B LPG Plus engines in vehicles certified to Large Non-road Spark-Ignited Certified
Regulations must follow the additional, emissions specific instructions on page 5.

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DOCUMENT OVERVIEW
Cummins Westport has developed the spark ignited, lean burn ISB 5.9G, B Gas Plus, C Gas Plus, B LPG Plus
and BGI engines. These engines are primarily for automotive applications with some approved industrial (non-
road) applications.
These Installation Requirements describe the unique features of the B Gas Plus, B LPG Plus, C Gas Plus and
BGI engines and how these features affect their installation. Use these requirements as a supplement to the
various Cummins Automotive Diesel Installation Requirements and specific Installation Requirements, that apply
to natural gas and propane (LPG) engines. Refer to the appropriate Engine Curves and Data Sheets for
additional information.
Additional information on the B Gas Plus / B LPG Plus, C Gas Plus and BGI engines can be obtained from the
engine Technical Package AEBs. Refer to AEB 10.91 B Gas Plus, B LPG Plus and BGI engines, AEB10.175
for ISB 5.9G, and AEB 10.174 for the C Gas Plus engine (Note: the C Gas Plus family was revised in 2009)

SERVICE ACCESSIBILITY
Providing quality service is essential in obtaining customer satisfaction. The service accessibility requirements in
AEB 21.19 should apply to the B Gas Plus, B LPG Plus and C Gas Plus engines where appropiate. The
following unique natural gas engine components require service and/or must be readily accessible:
- Spark plugs and ignition coils
- Low pressure fuel filter (for draining and changing filter)
- CCV Filter and pressure restriction indicator (when CCV is applied)
- Heated Oxygen Sensor (HOS)

LUBRICATION
These gas engines require specific, low ash 15W40 oil. Please refer to the engine owner’s manual for
specifications and approved oils.

AIR INTAKE SYSTEM

The air intake system requirements are similar to those for ISB, ISC, & ISL diesels. Refer to the engine data
sheet for airflow and performance data.
Special consideration is needed for air compressor intake (compressor air supply connection) plumbing on gas
engines due to mixing of fuel in the intake manifold section of the cylinder head. See ‘Air Compressor’ topic on
page 7.

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EXHAUST ADAPTERS
Applications currently using similar diesel engines will require minor modifications to adapt their exhaust
plumbing to these engines. Refer to the installation and option drawings for exhaust connection details.
The use of the Cummins supplied exhaust outlet adapter is mandatory, due to the need for the heated oxygen
sensor (HOS) and exhaust backpressure sensor plumbing. Please refer to the options book and Application
Engineering, regarding available configurations and options.
When the exhaust outlet adapter is oriented to connect to exhaust piping, the HOS must be at the top of the
exhaust adapter (+/- 80 degrees of vertical, with sensing tip down).
To avoid heat damage, the HOS body should be located away from the exhaust manifold.
The backpressure sensor tube must slope downward from the backpressure sensor.

EXHAUST SYSTEM
These engines are certified as indicated on the datasheet when equipped with the correct, specific catalysts
correctly mounted in the exhaust system. The engine rating datasheet and the dependent PE Option will
indicate the appropriate catalyst part number. These catalysts are different than the catalyst used on the diesels
and they are required on all applications.
The BGI was designed to meet EURO III certification only if the correct catalyst part number as shown on the
engine data sheet is used.
Use of a catalyst requires stainless steel exhaust piping and adapters, between the turbocharger and catalyst.
Installation recommendations for Natural Gas and LPG Catalysts are contained in AEB 21.20 (Natural Gas and
LPG Catalysts). This AEB should be used as a guide for any exhaust system design work.
The surface temperature and radiated heat from the engine and exhaust piping, is higher than with diesel
engines. Typical temperatures are between 1000°F & 1200°F. Fuel lines, hoses, wiring and rubber components
should be located away from the exhaust piping. Heat shields must be used if any components are within 12
inches of the exhaust piping, turbocharger, exhaust manifold or catalyst.

Insulation material must not be applied to any part the exhaust manifold or turbocharger assembly.

Note: The catalyst outlet temperature may be higher than the catalyst inlet temperature.

EXHAUST TEMPERATURE REQUIREMENT FOR BS IV, EURO 4, EURO 5 and EEV RATINGS ONLY
There is an additional exhaust system requirement that applies to certain engiena pplications by emissions
category. These include ISB 5.9G ratings, C Gas Plus Euro 4, and B Gas Plus Euro 5 and B Gas Plus EEV
certified ratings. For these applications, the maximum exhaust gas temperature drop from the turbocharger
outlet to the catalyst assembly inlet must be less than 25 degrees C ( 45 degrees F) when measured under the
Cummins Cooling Test operation conditions that are appropriate for the application.

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EMMISSIONS RELATED INSTALLATION INSTRUCTIONS FOR B LPG NON-ROAD ENGINES

There are specific additional instructions in 40 CFR 1068.105 that apply to the installation of B LPG PLUS
engines in a vehicle certified to Large Non-road Spark-Ignited Regulations.

Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.

The OEM must ensure that sampling of exhaust emissions will be possible after engines are installed in
equipment and placed in service. This requires that a 20-centimeter extension could be added to the exhaust
pipe to sample exhaust emissions in a way that prevents diluting the exhaust sample with ambient air.

If the OEM installs the engine in a way that makes the engine’s emission control information label hard to read
during normal engine maintenance, then they must place a duplicate label on the vehicle, as described in 40
CFR 1068.105

EXHAUST SYSTEM: HEATED OXYGEN SENSOR (HOS)

The internal grommet temperature of the HOS should not exceed 200o C (390o F), under any operating or
ambient conditions. In general, the maximum HOS temperature will occur on a very hot summer day, after at
least 1 hour of stop-and-go driving, with heavy acceleration and a fully loaded vehicle, but this varies by
application. Heat-soak conditions, after shutdown, can also cause very high temperatures and must be mea-
sured
The internal temperature of the HOS is measured with a special HOS sensor which has a thermocouple inserted
to measure the grommet temperature. This testing should take place during the IQA with an appropriate duty
cycle. A instrumented HOS may be obtained through Cummins Application Engineering. Figure 1 shows how
to instrument a HOS if neccessary.

Figure 1

NOTE: The OEM must use the exhaust outlet adapter supplied with the engine and the HOS cannot be moved
or relocated by the OEM.

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FUEL SYSTEM
Fuel pressure control is vital to the proper operation of the engine. In order to insure the engine operates
properly, fuel pressure must be delivered to the engine fuel inlet at the pressure and flow rate listed on the
engine data sheet.

For natural gas engines, fuel must be supplied to the engine inlet at a steady pressure +/-69 kPa (+/-10 psi)
variation between the minimum and maximum fuel inlet pressures liisted on the enigne datsheet. This pressure
must be maintained under all engine speed and load conditions and for tank pressure conditions from full to
empty.

Fuel temperature should be -40 C to 93 C (-40 °F to 200 °F).

For B LPG Plus – Liquid LPG/Propane must be supplied to the engine at a steady pressure +/- 34 kP (+/- 5 psi)
under all conditions (temperatures and fuel flow rates) and meet the fuel pressure requirments oulined on the
engine data sheet. For cold weather enviroment operation, a pressure assist vehicle fuel system may be
required to achieve the fuel pressure requirments (refer to AEB 21.53).

A low-pressure fuel filter is mandatory and is Cummins supplied. It is to be remote mounted and plumbed by the
OEM. Hoses used with the remote fuel filter arrangement must be approved for use with natural gas or
LPG/Propane. Use of a non-Cummins filter will invalidate any warranty applicable to the engine for the fuel
system components if poor fuel quality is found to be the cause of failure. The low-pressure fuel filter must be
located where it can be easily drained for meeting service drain intervals or as conditions require.

Note: The low pressure fuel filter drain location must not be directly above components such as starters,
electrical solenoids, etc, which can not withstand oil or water splash, or above the exhaust manifold.

Refer to the following AEBs for more information on specifc types of gaseous vehicle fuel systems:

AEB 21.17 Installation Requirments – LNG Fuel Systems

AEB 21.25 Installation Requirments – CNG Fuel Systems

AEB 21.53 Installation Requirments – LPG (Propane) Fuel Systems

COOLING SYSTEM
For design information to help specify the required engine cooling system refer to the engine data sheet for heat
rejection and flow information.
A pressurized surge (reservoir) tank is required. The engine coolant vent is plumbed to the surge tank and
check valves cannot be used in the vent line. The engine vent line connection point for low mount turbos, is
approximately the same as the diesels. However, for high mount turbo arrangements, the engine vent line
connection point is at the turbocharger. This line must not sag or dip, but be on an upward slope from the engine
to the surge tank.
Coolant supply for the high-pressure/1st stage regulator (CNG fuel system) or vaporizer (LNG fuel system) can
be taken from:
1. An available coolant supply port on the engine.
2. The cabin heater supply line, before any shut-off valves.
The coolant return line from regulator or vaporizer must be plumbed to the coolant circuit on the suction side of
the water pump (except fill line) and may not contain any shut-off valves.
For B LPG Plus – Coolant ports at the rear of the cylinder head MAY NOT be used for OEM coolant supply.
Coolant for accessories such as cab heaters should use the ports made available at the front of the head near
#1 cylinder near the thermostat housing.

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AEB 21.24 is supplemental information concerning charge air cooler installation recommendations.
Intake manifold temperature control is very important on spark ignited engines. The vehicle’s cooling system
fan control must have direct coolant temperature and intake manifold temperature sensing (Refer to AEB 21.38
for values) or use ECM fan control. The B Gas Plus, B LPG Plus, BGI and C Gas Plus engines have a fan
control feature available that can be used with on/off or variable speed fan drives.

ENGINE COMPARTMENT HEAT

Ventilation of the engine compartment is critical, due to increased radiated exhaust heat, as compared to the
diesel product. Provisions for airflow through the engine compartment, particularly at idle, are recommended.
Temperature cannot exceed 104 °C (220 °F) when measured at the ECM surface.
Special consideration should be given to catalysts, mufflers, exhaust piping, and associated mounting hardware,
which are mounted inside and outside the engine compartment. Fiberglass panels, wiring harnesses, etc, may
be affected by excessive heat, if the engine compartment is not adequately vented.

Insulation material must not be applied to any part the exhaust manifold or turbocharger assembly.

AIR COMPRESSOR

In 2007 the Cummins supplied air compressor inlet connections for turbocharged air supply from the fuel
module were discontinued for gas engine models. All air compressor plumbing must now be customer supplied
by connection to the vehicle air intake or air handling plumbing.

The air compressor supply air can be plumbed to the charge air cooler outlet to engine air intake OEM
connection pipe for a turbocharged (or boosted supply) version. The tapping location in the OEM pipe must be
at least 16 inches upstream of the fuel module when measured from the face of the engine connection casting
along the flow stream centerline of the tube and flex connectors. This will give 18” minimum separation
between the air connection and the critical engine sensors within the fuel module.

The air compressor supply air can be plumbed to the air cleaner outlet pipe/turbo inlet pipe for a naturally
aspirated version. This may be necessary if the requirements for turbocharged tapping location described
previously cannot be met.

See AEB 20.11 for detailed discussion of the specific applications requirements that apply to air compressor
options on Cummins engines. The air compressor intake hose must be of suitable diameter and material as
discussed in this AEB. All connections should be robust to avoid leakage and blowoff failures that would
compromise the air handling system integrity.

CAUTION: The compressor air supply must NOT be plumbed to the engine fuel module or engine intake
manifold so that an air/fuel mixture can enter the compressor.

IGNITION SYSTEM
The Ignition Control Module (ICM) provides a signal to the coils, which supply high voltage for the spark plugs.
The ignition system features single spark discharge and multiple spark discharge for optimization of power.

WARNING: The Ignition System can deliver up to 40,000 volts to the spark plugs. Extreme care should be taken
when working with this high voltage system.

The ignition system can withstand ambient temperature extremes from -40 C to 104 C (-40 °F. to 220 °F). The
ECM supplies information to the Cummins Ignition Module to provide the appropriate spark depending on
engine demand.

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A minimum of 152.4 mm (6 inches) of clearance above the valve cover is required for spark plug and ignition
coil removal. The spark plugs have been developed specifically for lean burn conditions and high-energy ignition
requirements (Refer to the Owner’s Manual for more information on the spark plugs).

WIRING HARNESS, FAULT LAMPS, STARTER SUPPLY, ENGINE PROTECTION, ACCELERATOR

PEDALS, SWITCHES, & POWER REQUIREMENTS
Please refer to AEB’s 15.35, 15.36, 15.37, & 15.38 (CM 556 Electronic Sub System Tech. Pkgs.) for all
electrical interfaces and requirements.

POWER TRAIN
For acceptable performance, the transmission should allow the engine speed to remain above peak torque rpm
after all full throttle up shifts.

The low speed response and governed speed differs from most of the ISB, ISC, & ISL diesel ratings, thus
special consideration to transmission model, the converter match (for automatic transmissions), transmission
gear ratios, and rear axle ratios is required.

Automatic transmissions with torque converters and manual transmissions with clutches are approved for use.
Any transmissions, or clutches, must be sized for the power rating selected.

Matching of driveline components is the same procedure as used with the diesels. Calculations should be based
on rated speed of the engine and matching the horsepower/torque curves for the selected power rating.

ENGINE BRAKE AND VEHICLE DRIVELINE RETARDERS

Engine compression or exhaust brake systems ARE NOT allowed. Driveline retarders or retarders in the
transmission can be used.

COLD STARTING AIDS

Cold starting aids, such as ether, which are introduced through the air intake system of the engine, can NOT be
used. Aids such as engine coolant heaters and oil pan immersion heaters are recommended for vehicles started
in temperatures below -12 C (10 °F)

These engines are designed to start unaided, at a temperature

of -12 C (10 °F) and above. However, cold start procedures/recommendations should be implemented per the
Owner’s manual when ambient temperatures fall below -12 C (10 °F). Care should be taken to allow the engine
to warm up until normal operating temperatures are achieved prior to placing vehicle(s) into service. Refer to
data sheet for starter selection requirements.

CLOSED CRANKCASE VENTILATION SYSTEM

The Closed Crankcase Ventilation System (CCV) is required for most gas engines that are discussed in this
document (some BGI ratings do not require CCV).

Crankcase vapors, or blowby gases, are those gases that escape past the piston rings during engine cycling.
These gases accumulate in the crankcase and in an open system vent into the atmosphere. A Closed Crank
Case (CCV) system recirculates the crankcase vapors back to the turbocharger inlet.

For more details on CCV requirements, see AEB 48.02.

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Change Date Revision History Pages

July 2009 Added references to new ISB 5.9G all
Aug 23 2007 Added air compressor plumbing discussion for required customer 3 and 7
supplied intake connections. Update to reference latest AEB 20.11 for
air compressor requirements.
June 2007 Added specific emissions related installation requirements for B LPG 4
Plus Large Non-road Spark-Ignited Certified Engines. This is required
for compliance with this certification category. Added by R Mason per
instructions of Scott Keen.
January 2007 B Gas Plus Euro 5/ EEV Temperature Drop Requirements Added, 4, 7
specified that no insulation can be applied to turbo or manifold.
July 2004 B Gas International (BGI) engine information added All
December, Edited AEB references 5
2002 Removed propane references 2
November 2002 Changes to HOS temperature limits identifying them as the internal 2&4
grommet temperature
Changes to include B LPG Plus All pages
May, 2002 Changes for C Gas Plus fuel pressure requirements and fan control for 1, 3, & 4
both B Gas Plus and C Gas Plus

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