PROPANE AUTOGAS

One of the best kept secrets in alternative fuels is right here in our own backyard.

90% of the propane used in the US is produced in the US. 33% of the world supply is from Texas.

Fuel costs up to 50% less than gas and 30% less than diesel.

Infrastructure cost drastically less than other alternative fuels.

Propane autogas burns clean and potentially reduces maintenance costs and extends engine life.

Economical

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Ford 6.8L-3V Engine & 6R140 Transmission

“A Relationship that Began Over 80 Years Ago”

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6.8L-3V Engine Background

The 6.8L-3V engine is produced in Windsor Ontario.• 2.1 million square feet• 1850 employees

The 6.8L engine was introduced in 1997. An upgraded version of the engine was introduced in 2005 with 3 valves per cylinder (2 intake, 1 exhaust).

The 6.8L engine is currently used in Super Duty trucks (F450 – F550), Econoline vans, strip chassis, motorhomes and commercial step vans. Over 1 million 6.8L engines have been produced since its introduction.

The engine was upgraded with premium valves, valve seats and a larger oil pump to meet Blue Bird’s needs.

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6.8L-3V Key Features

Electronic Throttle

Cast Stainless Manifolds

Two Intake Valves per Cylinder

Aluminum Heads

Oil CoolerCast Iron Block

Premium Exhaust Valves (Inconel)

Other Features• Knock Sensors• Balance Shaft• Fail Safe Cooling

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6.8L-3V Technical ComparisonGM 8.1L Ford 6.8L-3V Advantage

Displacement 8.1L 6.8L Ford - Fuel Economy

Horsepower 330 hp 362 hp Ford - Performance

Torque 450 ft-lbs 457 ft-lbs Ford - Performance

Compression Ratio 9.1:1 9.2:1 Ford - Fuel Economy

ValvetrainPushrod

(2 valves per cylinder)Overhead Cam

(3 valves per cylinder)Ford - Performance

Weight 727 lbs 620 lbsFord - Performance & Fuel Economy

Throttle control Electronic Electronic Equal

Block cast iron cast iron Equal

Cylinder Head cast iron aluminum Ford - Weight

Intake Manifold cast aluminum composite Ford - Weight

Exhaust Manifold cast stainless steel cast stainless steel Equal

Crankshaft cast nodular iron Forged steel Ford - Strength

Connecting Rods forged steel Powdered Metal Ford - Weight

Ignition Coil pack Coil on Plug Ford - Reliability

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6.8L-3V Durability

The original 6.8L-3V gas engine was designed for a minimum of 10 year / 150,000 mile durability under the most strenuous customer conditions.

Feedback from gasoline fleet customers indicates they routinely see 250k miles with no major issues.

The Blue Bird LPG 6.8L-3V has been upgraded with premium valves and valve seats. In addition, the engine has been installed with a larger capacity oil pump to maximize lubrication and aid in cooling.

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6R140 Background• The 6R140 transmission is produced in Sharonville Ohio:

– 2.4 million square feet– 1670 employees

• The 6R140 is an all new product that Ford engineered over 4 years. It went into production in late 2009.

• It is currently used as the only transmission in Ford’s Super Duty pick-up (F250 – F550):– 6.2L gas (405 ft-lbs, 385 hp)– 6.8L gas (457 ft-lbs, 362 hp)– 6.7L diesel (800 ft-lbs, 400 hp)

• The transmission was upgraded for both Ford’s medium duty F650 program and for Blue Bird.

250,000 units per year

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6R140 Technical Overview• 6-speed rear wheel drive transmission• Builds on proven architecture used on other Ford 6-speed Rear wheel

drive applications• Structure capable of up to 900 ft-lbs of engine torque

– Blue Bird 6.8L engine produces 457 ft-lbs.• Input RPM capability (max/min): 6500/525

– Blue Bird 6.8L engine speeds are between 760 and 4750 rpm • Torque converter can be locked at 900 rpm providing improved fuel

economy• 5.899 ratio span allows for best in class launch capability and fuel

efficiency

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Proven powerflow provides close ratio gearing for seamless shifting and a double-overdrive to help keep you in the power sweet spot for optimum performance and fuel economy

Class exclusive Live Drive PTO directly links the PTO Output gear to the engine output making power available anytime the engine is running, significantly improving productivity and usefulness during start-stop operation

Tested tough and varified durable for over 250,000 miles of some of the toughest Super Duty operating conditions.

High Energy Friction Plates are engineered with fluid lube paths to improve cooling, wear resistance and to reduced fluid churning to minmize torque loss.

New High capacity, high efficiency fluid filter keeps the fluid running cleaner longer to extend fluid change intervals up to 150,000 miles.

All new Torque Converter with low speed lock up capability -down to 900 RPM - enabling the engine to run efficiently at any rpm for improved fuel economy.

Bigger Stronger Gears with a Lower first gear ratio for improved launch performance eund uncompromising tow-haul durability

High Strength Cinter metal carrier with patented Ford rocker one-way clutch is desinged to easily handle the enormous low-end torque of the diesel engine and the high speeds of the gas engine

6R140 Key Features

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6R140 Feature Comparison to Allison:

• Both the Ford 6R140 and Allison are 6-Speed Automatics with double-overdrive and electronic controls

• In addition, 6R140 Offers:– Shift speeds up to 6250 rpm – Allison is limited to ~3,300 rpm – Approximately ~30 lb. weight advantage (375 lbs. vs. ~345 lbs.)– Posilok Torque Converter, provides improved fuel efficiency with

enhanced control of lock-up clutch and better lugging capability compared to the open-piston Allison design

– High energy, Low drag friction material which reduces parasitic losses for improved fuel economy.

– High efficiency Filter w/ 150,000 mile change interval– GCW capability up to 37k lbs versus 33k lbs for the Allison 2000 Series

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6R140/Allison Comparison(Engine Torque vs. GCW)

Note: Allison data taken from their website

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900

0 5 10 15 20 25 30 35 40

Max GCW (1000 lbs)

Max

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gin

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orq

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lbs)

Allison 1000 series Allison 2000 series

6R140 Capability

Blue Bird 6.8L-3V

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6R140 Durability Testing

Original 6R140 Testing (800 ft-lb diesel)

• 6.7L Diesel – 800 ft-lb Super Duty Testing– Successfully completed ten (10) 250,000 mile representative life tests with 800 ft-lbs of engine

torque in a 36,000 lbs vehicle– The Blue Bird program has a max engine torque of 457 ft-lbs and 33,000 lbs

• A full 250k mi equivalent Gear Life Test was successfully completed after completion of 250k mile representative trans life test (total of 500k miles)

• Three Transmission life tests extended to 350k equivalent miles with no issues

• Commercial Duty Transmission Upgrade Testing– Test completed 350k miles with no issue

5 Year/100,000 Mile Ford Engine/Transmission Limited WarrantyFor Blue Bird Corporation School Buses

Ford Motor Company (Ford) is providing a 5 year/100,000 Engine/Transmission Limited Warranty on eligible Blue Bird Body Company (Blue Bird) school buses. Ford will provide for the repair, replacement, or services of covered components on the school buses during this Limited Warranty period in accordance with the following terms, conditions, and limitations.

1. Ford Engine/Transmission Limited Warranty. Under the Ford Engine/Transmission Limited Warranty, You are provided with 5 years of coverage from the original customer delivery date as provided to Ford by Blue Bird or up to 100,000 miles on the odometer, whichever occurs first. 2. Eligible Vehicles. 2012 – 2017 model year Blue Bird school buses equipped with the Ford 6.8L – 3V engine assembly and the Ford 6R140 transmission assembly.

3. Repairs Covered Under The Ford Engine/Transmission Limited Warranty. Your Blue Bird Dealer, a Ford authorized dealership or other service provider authorized by Ford will repair, replace or service all covered components, as specified on page 2, that fail due to defective material or workmanship during the applicable Ford Engine/Transmission Limited Warranty period. Parts and services not covered under the Ford Engine/Transmission Limited Warranty are listed on page 2.

4. Component Protection. Components covered by the Ford Engine/Transmission Limited Warranty are shown on page 2.

5. Where To Go For Covered Repairs. Contact your Blue Bird Dealer to obtain service for your Blue Bird bus. Your Blue Bird Dealer will help arrange for repair, replacement or service of engine or transmission components covered by this Ford Engine/Transmission Limited Warranty by a Blue Bird Dealer, a Ford authorized dealership, or other service provider authorized by Ford.

Propane School Bus Fact Sheet

Local Benefits of Propane Powered School Buses: 1. Lower Emissions:

Studies show that more than 70% of ambient air pollution comes from diesel emissions alone. 1 2 Diesel particulates are dangerous because they are so tiny, and can lodge into the deepest areas of human lungs. Children, in particular, are susceptible because they breathe 50 percent more air per pound of body weight than adults. 3

a. Propane powered buses emit virtually zero particulate matter.4 In essence, this is a 100% decrease in unhealthy particulate emissions when compared to diesel school buses.

b. By running propane powered buses, your district will reduce their local Carbon Dioxide Emissions by around 311,000 lbs per year. *Assume 15,000 miles per year on 35 buses.

c. Propane is nontoxic, non-carcinogenic, and is not considered a greenhouse gas if purged. In the unlikely event of a propane leak or spill, (unlike gasoline and diesel) propane does not harm the environment and is not a groundwater contaminant.

2. Impact Energy Security and Local Economy:

98% percent of propane comes from North American production. The main sources for propane are Natural Gas (80%) and Crude Oil (20%).

a. Propane currently contributes more than $554 million to the Wisconsin economy, and the industry employs more than 1,430 people in Wisconsin alone. 5

b. By operating propane powered buses, your district will replace imported diesel consumption with 116,000 gallons of domestically produced propane autogas per year. *Assume 15,000 miles per year on 35 buses.

3. Safe Transportation: Propane Tanks are made of ASME certified ductile carbon steel, whereas, gasoline and diesel tanks are made of a hardened blow molded plastic.

a. Propane Tanks are 20 times more puncture resistant than gasoline and diesel tanks. b. Auto-ignition: Propane has a much higher auto-ignition temperature when compared to

gasoline and diesel. This means the minimum temperature of a spark must be much higher in order for propane to combust, whereas gas and diesel can ignite with a relatively cool spark: Propane: 842° F / Diesel: 494° F / Gasoline: 530° F

c. Flammability Range: The range of air to vapor in which propane will ignite is narrower than that required for gasoline or diesel. Ratios for air to fuel ignition (rich limit ÷ lean limit): Propane: 4.5:1 / Diesel: 12.5:1 / Gasoline: 5.5:1

1 Solomon, Gina M., et al. “No Breathing in the Aisles: Diesel Exhaust Inside School Buses.” National Resources Defense Council and the Coalition for Clean Air. January 2001 27 April 2004 <http://www.nrdc.org/air/transportation/schoolbus/sbusinx.asp>. 2 Nazemi, Mike A. “Multiple Toxics Exposure Study (MATES-II) in the South Coast Air Basin.” U.S. Environmental Protection Agency, Office of Science Policy (OSP), South Coast Air Quality Management District. Sampling Period: April 1998 to March 1999. 29 April 2004 <http://www.epa.gov/osp/presentations/airtox/nazemi.pdf>. 3 “Health and Environmental Effects of Particulate Matter.” U.S. Environmental Protection Agency, Office of Air & Radiation (OAR), Office of Air Quality Planning & Standards. 17 July 1997. Last updated on Thursday, July 11th, 2002. 29 April 2004 <http://www.epa.gov/ttn/oarpg/naaqsfin/pmhealth.html>. 4 “Clean Cities Propane Overview,” U.S. Department of Energe (DOE), 11 December 2012. www1.eere.energy.gov/cleancities/toolbox/.../propane_overview.ppt.. 5 “Study of the Propane Industry’s Impact on U.S. and State Economics,” Environmental Analysis, Inc, November 2004

Mesa Public Schools Saves 32 Cents per Mile with Propane Autogas

Omaha Public Schools to Run More Than 400 Buses on Propane Autogas

Dairyland Bus Company Loses Contract for Waukesha Schools While First Student’s bids came in at $6.33 million for diesel fuel and $6.14 million for propane

fuel with an assumption that 50 percent of buses are run on propane fuel

First Student Adds Nearly 135 Propane Autogas-Powered Buses to Pacific Northwest Fleet

FIRST STUDENT ADDS 86 PROPANE SCHOOL BUSES TO PORTLAND FLEET

Bozeman schools would switch to propane buses if new contract with First Student is OK’d

The first-year costs in four bids were: First Student with propane buses, $1.86 million; First Student with diesel, $1.98 million; Durham School Services, $2 million; and Karst Stage, $2.3 million

School District Saves More than $67K with Propane School Buses

WRITTEN BY RYAN GRAY

TUESDAY, 19 JUNE 2012 08:15

Eastern Carver County Schools in Minnesota says it saved more than $67,000 during the 2011-2012 school year alone by switching to propane power for its transportation fleet

Propane buses creating savings for District 112According to Brett Johnson, director of communications and community

relations, 18 of the district’s 102 buses had propane engines during the last school year, which led to savings of more than $67,000 in fuel

PROPANE SCHOOL BUSES IN WISCONSIN

SEPTEMBER 2012 FOUR PROPANE POWERED SCHOOL BUSES

SEPTEMBER 2013 150 PROPANE POWERED SCHOOL BUSESPRIGGE’S SCHOOL BUS SERVICE – SHEBOYGAN, WI. FIRST WISCONSIN CONTRACTOR TO PURCHASE PROPANE POWERED BLUE BIRD VISION “So Far we are very pleased with our propane school buses. Our drivers and student passengers just love the almost instant heat on cold winter days. The drivers like the way they handle …. And there is little to no noise while driving. The best part is no smelly diesel exhaust.”

Annual Miles 15,000.00 15,000.00 15,000.00

Total Miles in Life 180,000.00 180,000.00 180,000.00

Average MPG 71 Pass 6.00 7.00 4.00

71 Pass Gallons Consumed Annually 2,500.00 2,142.86 3,750.00

71 Pass Gallons Consumed Total 30,000.00 25,714.29 45,000.00

Diesel Price Per Gallon $3.65 $3.65

Propane Price per Gallon $1.45

Oil Interval 3,500.00 6,000.00 6,000.00

Oil Capacity 30.00 17.00 7.00

Oil Filter Cost $28.00 $5.00 $5.00

Oil Cost per Quart $1.50 $1.50 $1.50

71 Pass DEF Gallons (2%) 514.29

DEF Cost per Gallon $1.89

PM's Over Life 51 30 30

Labor Hours per PM 1 1 1

Hourly Labor Cost $30.00 $30.00 $30.00

Fuel Filter Change Interval 12,000 12,000 50,000

Fuel Filter Cost $60.00 $20.00 $113.00

Total Filter Changes 15 15 3.6

71 Pass Lifetime Fuel Cost $109,500.00 $93,857.14 $65,250.00

71 Pass Lifetime PM Cost $6,197.14 $3,087.00 $1,771.80

71 Pass TOTAL $115,697.14 $96,944.14 $67,021.80

PM Comparison

Lifecycle Costs

Type C School Bus180,000 Mile Lifecycle Cost Comparison

IC Diesel BB Diesel BB Propane Autogas

Gallon Comparison