CITY BUS IN PERFECTION - Ordem Dos Engenheiros

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CITY BUS IN PERFECTIONThe new MAN Lion‘s City.Ready for Euro 6d

bus & coach enginesEuro 6d(model year 2018-2020)MAN Truck & Bus Product Marketing, May 22nd, 2018

Introduction

Euro 6dWhat is exhaust emission regulation Euro 6d all about ?Control of exhaust gas emission For Euro 6d the same stringent On-Board-Diagnostics (OBD) andemission control demands apply as for Euro 6c. Permissable deviation of urea content in AdBlue significantlyreduced Lowering of OBD threshold for nitrogen oxides (NOx) Additional control of OBD function (IUPR In Use PerformanceRatio). Euro 6d shows different frame conditions for PEMS (PortableEmissions Measurement Systems) which was introduced for Euro6commercial vehicles Mandatory from 01.09.2018 for new vehicle types(new EG-type approval) Mandatory from 01.09.2019 for all new registered vehiclesMAN Truck & Bus Product Marketing, May 22nd, 2018PEMSduringwarm up 4

Euro 6dWhat is exhaust emission regulation Euro 6d all about ?Demands for On-Bord-Diagnostics (OBD) and control of exhaust gas emissions limits up to Euro 6dDemandEuro 6a–bEuro 6cEuro 6dControl of particulates OBD- limit (warning cascade)25 mg/kWh25 mg/kWh25 mg/kWh1 500 mg/kWh1 200 mg/kWh1 200 mg/kWh900 mg/kWh460 mg/kWh460 mg/kWh50 %50 %50 %noyesyesIUPR – monitoring of OBD- diagnosis frequencyMonitoring-PhaseIUPR 0,1(per OBD-family and vehiclesegment)IUPR 0,1(per OBD-family and vehiclesegment)at payload50 %50 %10 – 100 %Valued engine power 20 % 20 % 10 %Operating conditionsHot engineHot engineMonitoring duringwarming upOBD- limit NOxQuality deviation of AdBluePermissible deviation of AdBlue consumption - validationOBD- control of injector wearPEMS-measuringMAN Truck & Bus Product Marketing, May 22nd, 2018 5

Euro 6dWhat is exhaust emission regulation Euro 6d all about ?Mobile emissions measuring PEMS aggravated PEMS (Portable Emissions Measurement Systems), AKA In-UseConformity is to ensure that all components of the exhaust gastreatment systems work effectively throuhout their lifetime and arenot being negatively influenced through aging processes. Legal requirements demand a six year period, alternatively 300 000km. PEMS-measurements within Euro 6c were carried out with avehicle at normal operational temperatures, loaded from 50% to60% of max. payload, as well as a well defined route, i.e. 20% citytraffic, 25% intercity and 55% highwayMobile exhaust gas measuring device PEMS PEMS-measurements within Euro 6d are carried out with a vehiclefrom cold start up to normal operational temperatures. Additionalload ranges from 10% to 100% of max. payload, as well as differentroute profilesMAN Truck & Bus Product Marketing, May 22nd, 2018Advantages As commercial vehicles are being tested on the road– different topassenger cars – irregularities of exhaust gas values are impossible Environmental protection is ensured under real-life conditions 6

Euro 6dWhat are the technical changes in order to fulfill Euro 6d?Conflict of fuel consumption and noxious emissions Combustion at lowest possible fuel consumption and highestefficiency shows reduced particulate mass and CO2 figures buthigher NOx values. Starting with model year 2019 MAN modified its engines in order tosolve this conflict as well as to fulfill legal demands, targetingminimum fuel consumption In order to internally stabilize exhaust gas temperatures (also inlow duty operation) MAN D26 engines (SCR with EGR) feature anenhanced thermo management, an improved Common-Railinjection system and a new EGR-module. D08 engine will beavailabe as a SCR-only engine without EGR. D15 engine wasdeveloped from scratch and shows many new features. External exhaust gas treatment reduces NOx-emissions bymeans of a SCR-catalyst (Selective Catalytic Reduction),particulates are being removed by means of the MAN CRT(Continuously Regenerating Trap) filter systemNOxCO2In-engine conflict of NOx and PM mass in exhaust gasMAN engine types designed for actual vehile range (model year 18 – 20) are fulfilling Euro6d demands by means of a highly efficientexhaust gas aftertreatment.MAN Truck & Bus Product Marketing, May 22nd, 2018 7

Euro 6dWhat are the technical changes in order to fulfill Euro 6d?MAN Euro 6d introduction strategy While integrating new Euro 6d engines in their vehicles, MANintroduces several measures to lower fuel consumption andimproves R & M management. This includes: Development of new fuel filters for D08, D15 und D26 Euro 6dengines Combustion system optimizations (i. e. no-leakage injectionsystem, increase of cylinder end pressure; not D08) Driveline-embracing control of engine cooling including newcontrollable coolant pump (D15 and D26) Improved air compressor for all Euro 6d engines Development of airless SCR-dispensing systems for all engines(introduced already for D08 Euro 6c SCR without EGR) Reduction of exhaust gas treatment variants by means of a kitincluding only 2 basic variants (small, mid-size) of silencers,covering all Euro6d applications for trucks and busesenhanced engine MAN D2676 Euro 6dMAN Truck & Bus Product Marketing, May 22nd, 2018 8

Engine – portfolio

engine– portfolioMAN Bus engines Euro 6dSkylinerLion‘s IntercityLion‘s Intercity(from 12/19)Lion‘s City (L3C)until 12/22Lion‘s City (L4C)Lion‘s Coach / Tourliner /Cityliner510Lion‘s City (L3C) until 12/22470430D0836 – 6,9 L(SCR OHNE AGR)MAN Truck & Bus Product Marketing, May 22nd, 2018D2066 - 10,5 L (SCR MIT AGR)1 050 NmE2876 - 12,8 LNeu mit Euro 6d::Leistung je 10 PSDrehm. je 100 NmD2676 – 12,4 L(SCR MIT AGR) 10 375 kW1 250 Nm346 kW272200 kW346 kW1 800 Nm1 700 Nm1 600 Nm316 kW265 kW243 kWD1556 – 9 L(SCR OHNE AGR)310280294 kW1 600 Nm1 400 Nm1 200 Nm235 kW213 kW1 150 Nm1 050 Nm184 kW2801 250 Nm206 kW2503202 600 Nm2 400 Nm2 200 Nm316 kW330320290360228 kW360

engine– highlights Euro 6d

engine – Highlights Euro 6dHighlights of MAN Euro 6d engines (Bus)Optimized driveline concept New: higher engine power for D26 (SCRwith EGR) Power increase: 10 bhp Torque increase: 100 Nm New: D15 Euro 6d (SCR without EGR)replaces D20 Euro 6c (SCR with EGR), allvariantsSimplified exhaust gas treatment New: reduction of variants New: airless SCR- dispensing system Refined enginesNew: LIN-generator for all Euro 6denginesNew: fuel saving air compressor for allEuro 6d enginesNew: 1-step turbo charger for D26 andD15New: Common-Rail-(CR)-componentsNew: cumbustion chamber layout for D26New: EGR-module for D26Improved performance New: Optimized thermo management tofulfill Euro 6d legal demands New: Cold start ability up to – 32 Cwithout flame start unit for D15 engineAdapted service interval calculator New: increased max. change intervals forengine oil and particulate filter (DPF),depending on operationfuels New: 2-step fuel filter system New: Approval for paraffinic fuels (i. e.HVO) for Euro 6dremarks: shown features not inevitably available for all engines. D15 newly designed for Euro 6d.MAN Truck & Bus Product Marketing, May 22nd, 2018 12

engine – highlights Euro 6dOptimized thermal managementRequirements Ensuring high exhaust gas temperatures is a new requirement inorder to fulfill the stringent legal Euro 6d demands. This is inevitable,as PEMS- measurements are being carried out from cold start aswell as additional pay loads from 10% up to 100%. MAN ensures compliance by means of an optimized thermalmanagement, mainly including the following measures: Controlled exhaust butterfly valve for all Euro 6d engines Controlled coolant pump for D26 and D15 engines (a rigid coolantpump is available optionally ) Fan speed sensoring and optimized oil cooler includingthermostat13241 ECU, i. e. PTM, EDC2 Combustion engine3 Controlled coolant pump4 Cooling fan incl. speed sensoringGeneral overview: components for engine thermal managementMAN Truck & Bus Product Marketing, May 22nd, 2018 13

engine – highlights Euro 6dApproved fuels for MAN Diesel engines Euro 6d (Bus)Diesel fuelBiodiesel fuel FAME MAN Diesel engines can be operated with the following fuels: European Norm EN 590 DIN EN 590 (Germany) British Standards BS 2869 Class A1 (GB) ÖNORM EN 590 (Austria) ASTM D 975 No. 1 D (USA) As an alternative to fuel based on fossil oil Biodiesel is important,which is known as FAME. It is approved for D08, D20 and D15engines. Euro 6d requires a maximum sulphur content of 10 ppm, a watercontent of max. 200 ppm and a total fuel contamination of max.24 mg/kg. FAME (Fatty Acid Methyl Ester) fuels are categorized as „Biodiesel“they are industrial produced fuels from regenerative raw materials,fulfilling European Standard EN 14214.Technical releases from MAN for engine operation with BiodieselFAME relate to EN 14214. FAME shows different evaporation caracteristics and hence causesirreversible oil dilution. Therefore engine oil change intervals mustbe reduced when operating with biodiesel. MAN does ask for aService Warranty Module to be purchased. Mixing FAME with standard Diesel (B7) is uncritical: EN 590standard does allow for a 7 vol-% content of FAME. Use of B100 (100 % Biodiesel) is possible for numerousvehicle/engine configurationsMAN Truck & Bus Product Marketing, May 22nd, 2018 14

engine– highlights Euro 6dApproved fuels for MAN Diesel engines Euro 6d (Bus)Paraffinic Diesel fuel HVOAdvantages Another alternative to fuel based on fossil oil is HVO (engl.:Hydrotreated Vegetable Oil) according to European StandardEN 15940 . HVO is approved for all MAN Euro 6d engines. No expensive engine modifications (fuel lines, injectors, seals)necessary HVO is a second generation synthetic fuel, which is produced fromhydrating vegetable oils as well as animal fatt or used cooking oil. HVO raw material origins from certified cultivation and thereforedoes not compete with food production. Service intervals stay unchanged (engine oil, particulate filter) No negative impacts concerning driveability (unchanged power) No negative impact concerning warranty conditions As hydration is already part of fossil fuel production HVO productioncan easily be integrated in an existing refinery.MAN Truck & Bus Product Marketing, May 22nd, 2018 15

Motoren – Highlights Euro 6dApproved fuels for MAN Diesel engines Euro 6d (Bus)Fuel comparisonfeaturesDiesel fuelBio diesel fuel FAMEParaffinic diesel fuel HVOAppliccable standardEN 590EN 14214EN 15940Homologation available(necessary from Euro 6)YesOn requestYesMAN engine approvalYesWith Service Warranty ModuleYes Sulphur freeAdvantage Good availability Environmentally friendly Good fuel station network Quick biological degradeability General approval Sinificantly better carbon footprintcompared to fossil fuel No engine and periphery modificationsnecessary Tax benefits in different markets Lower energy content than standarddiesel, therefore higher consumption Reduced engine powerDisadvantage High tax duty Reduced fuel evaporation Partial availability Reduced service intervals (Engine oil,DPF) OEM approval uncertainMAN Truck & Bus Product Marketing, May 22nd, 2018 16

engine– D15 (SCR only)

MAN D15 engineMAN Truck & Bus Product Marketing, May 22nd, 2018 18

MAN D15 engineNew engine generation MAN D15Positioning Official name: MAN D1556 LOH 9-l- engineD1556 LOH Euro 6d with 280, 330 and 360 bhpas ideal size, completing 6,8-l- engine D0836 LOH Euro 6d with 290 bhp and 10,5-l- engineD2066 LUH Euro 6d with 400 bhp concept: one engine suits for all city buses one model (vertical) reduces number of variants one exhaust gas aftertreatment system Integration of vertical engine in „engine tower“ in the left rearThe new 9-litre- engine represents the perfect ratio in terms ofengine size/ weight and power/ fuel consumptionMAN Truck & Bus Product Marketing, May 22nd, 2018 19

MAN D15 engineNew engine generation MAN D15Customer benefits Higher payload due to reduced engine weight allows for increasedpassenger number (D15 LOH versus D20 LUH). Down-sized and thermodynamic optimized engine allows forreduced fuel consumption Easy access to all engine service points allows for simplified repairand maintenance Modular engine design reduces R & M costsMAN Truck & Bus Product Marketing, May 22nd, 2018 20

MAN D15 engineTechnical detailsfoamed harnessesexcellent accessabilityto service points(engine oil - and fuel filter)injection pressure up to 2 500 barcombustion pressure up to 230 bar,new valves, forged pistonbillet steel camshaftcontrolledwater pumpcontrolled butterfly valve forcharge airadapted belt drive(when operated without generator)separate belt drive (for 2ndgenerator operation)1 or 2 LIN-generators(for optional CSGno respectively 1 LIN-generator)separate belt drive for A/CcompressorMAN Truck & Bus Product Marketing, May 22nd, 2018engine ECU (EDC17, DENSO)2 cylinder-/ 2-step aircompressorsteering pump(mounted to air compressor)A/C compressormounted to weight optimized consolemade of aluminium 21

MAN D15 engineTechnical detailsauxiliary power take-off 2(with optional hydro pump)auxiliary power take-off 1(with controlled hydro pump fandrive)crankshaft-starter-generator(CSG, optional)MAN Truck & Bus Product Marketing, May 22nd, 20182-step fuel filter system(main fuel filter on engine)1-step turbo chargerwith wastegatecontrolled butterfly valve forexhaust gas24-V-starter for cold start 22

MAN D15 engineTechnical detailsEngineD1556EmissionEuro 6dNumber of cylinders / Design / Valves per cylinder6 / in-line / 4Displacement (l) / Stroke (mm) / Bore (mm) / Compression ratio9 / 145 / 115 / 21:1Injection systemRated power (kW/bhp)Internal engine nameCommon Rail206/280LOH12243/330LOH11265/360LOH10Rated speed (1/min)1 8001 8001 800Rated torque (Nm)1 2001 4001 600800 – 1 600900 – 1 600900 – 1 550550550550Engine weight1) (kg)app. 900app. 900app. 900Engine oi volume without / with oil filter (l)39 / 40,539 / 40,539 / 40,5up to 80 000 / 470 000up to 80 000 / 470 000up to 80 000 / 470 000up to 2 500 / 230up to 2 500 / 230up to 2 500 / 230up to – 32up to – 32up to – 32At engine speed (1/min)Minimum idle speed (1/min)Oil change interval2) / cleaning interval DPF3) (km)Injection pressure / Combustion pressure (bar)Cold start ( C)1)Engine weight without oil & coolant2)Only with engine oil according to M 3677 standard.3)Under ideal operational conditions, figures can even be exceeded.MAN Truck & Bus Product Marketing, May 22nd, 2018 23

MAN D15 engineEngine performance diagramsD1556 LOH12 206 kW/280 bhpMAN Truck & Bus Product Marketing, May 22nd, 2018D1556 LOH11 243 kW/330 bhp 24

MAN D15 engineEngine performance diagramsD1556 LOH10 265 kW/360 bhpMAN Truck & Bus Product Marketing, May 22nd, 2018 25

The new Lion’s City with optional MAN EfficientHybridSystem concept The optional MAN EfficientHybrid equipment provides the new Lion’sCity with an intelligent energy management system for increasingefficiency and improving travel comfort. The central component of this innovative hybrid system is thecrankshaft starter-generator (KSG) incorporated in the drivetrainbetween the engine and the transmission.Advantages The crankshaft-starter generator is a robust and non-wearing electricmotor that can operate both as a generator (alternator) duringpropulsion or braking and conversely also as a starter. The electrical energy stored in the electric rooftop components of thehybrid system can also be used to supply consumers in the 24V electricalnetwork of the new Lion’s City.Customer benefits Start-stop operation creates additional fuel savings and enhanced travelcomfort When the engine stops, no pollutants are emitted at the bus stop, andthe bus starts quickly and silently when moving off againMAN Truck & Bus AG Product Marketing, May 22nd, 2018 26

System overviewThe new Lion’s City with optional MAN EfficientHybrid24 on:3Ground 48 VDC24VStarterCrankshaft StarterGeneratorUltraCap energystorage device2Inverter424V batteryElectrical system loadDC/DC converter48 VDC2431CSG48 VAC148 VDC, groundedDC/DC converter, UltraCap energy storage device, inverter, crankshaft starter-generator (KSG), wiringStop/start, recuperation, 24V vehicle electrics supplyMAN Truck & Bus AG Product Marketing, May 22nd, 2018 27

MAN Academy Station Chassis & Powertrain EfficientHybridSystem componentsCrankshaft Starter-Generator1Construction21 Connecting cables2 Terminal box3 Housing4 Stator3455 Rotor: Mounting ring6 Rotor: Laminated core7 Rotor: Rotor carrier ( flywheel)MAN Truck & Bus AG Product Marketing, May 22nd, 201867 28

MAN Academy Station Chassis & Powertrain EfficientHybridSystem componentsCrankshaft Starter-GeneratorTechnical specifications Type of motor:Air-cooled reluctance motor, three-phase switched Power:PCont 8kW (continuous power)PPeak 12kW (peak power) Starting torque:520NmCrankshaft starter-generator fitted to D1556 engineMAN Truck & Bus AG Product Marketing, May 22nd, 2018 29

MAN Academy Station Chassis & Powertrain EfficientHybridSystem componentsSystem components on vehicle roof To facilitate optimum cooling, electric and electronicpower components for energy storage andconversion are placed beneath the roof hood of thenew Lion’s City with MAN EfficientHybrid (4).1 UltraCap energy storage4unit (48VDC)2 Inverter(48VAC/48VDC)323 DC/DC converter(48VDC/24VDC)Advantages4 Roof hood with openings The roof hood: Provides mechanical protection of the powercomponents (1) to (3), Contains aerodynamic openings for optimum flowof cooling air flow Acts as a touch guard when using the roofemergency exit located at the rear (5).5 Emergency roof exitMAN Truck & Bus AG Product Marketing, May 22nd, 20181for cooling45241 30 3

MAN Academy Station Chassis & Powertrain EfficientHybridSystem componentsInverter ( 30VAC/ 60VDC) The inverter (2) transforms the electrical energybetween the crankshaft starter-generator (1) and theUltraCap energy storage module (3). Propulsion phase (recuperation of brakingenergy):The three-phase alternating voltage of 30VACproduced by the crankshaft starter-generator ingenerating mode is converted to the UltraCap DCvoltage of 60VDC. . Startup phase:UltraCap DC voltage of 60VDC is converted backto thethree-phase alternating voltage of 30VAC requiredby the crankshaft starter-generator.MAN Truck & Bus AG Product Marketing, May 22nd, 201823231 Crankshaft starter-generator(48VAC)2 Inverter(48VAC/48VDC)3 UltraCap energy storage unit1(48VDC) 31

MAN Academy Station Chassis & Powertrain EfficientHybridSystem componentsDC/DC converter ( 60VDC/24VDC) To supply the vehicle electric network while travelling, the crankshaftstarter-generator of the MAN EfficientHybrid system normallyfunctions as a generator. The inverter converts the 48V AC voltagefrom the starter-generator to DC and feeds this to the 48Vintermediate circuit.432615 The DC/DC converter (2) transforms the energy stored ( 60VDC) inthe UltraCap module (1) to the on-board vehicle electrics voltage(24VDC). The power from the UltraCap module is used for: Charging the vehicle battery (3) Supplying the vehicle electric network (4) Generator equipment: 1 x 120A with optional MAN EfficientHybrid with18m articulated bus or 12m single bus with many consumers Without generator, with optional MAN EfficientHybrid with12m single bus1 Energy storage unit (48VDC)2 DC/DC converter(48VDC/24VDC)23 Vehicle battery (24VDC)14 Vehicle electric network (24VDC)5 Starter (24VDC)6 LIN three-phase generator(with inverter for 24VDC)MAN Truck & Bus AG Product Marketing, May 22nd, 2018 32

MAN Academy Station Chassis & Powertrain EfficientHybridSystem functionMAN EfficientHybrid with stop-start function and recuperation In propulsion phases, the starter-generator generates electr

Lion‘s Intercity Lion‘s Coach / Tourliner / Cityliner Lion‘s City (L3C) Lion‘s City (L4C) until 12/22 Lion‘s City (L3C) until 12/22 Skyliner Lion‘s Intercity (from 12/19) 1200 Nm 1 400 Nm 1 600 Nm 1 050 Nm 1 250 Nm 200 kW 228 kW

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