Professional Documents
Culture Documents
Reference Book
(Launch Groups 1 through 4)
Fort Mill, SC
July 2009
Author: Tarcan Tarman
Product Strategy
Table of Contents
EPA 2010 Overview
Engines
11
Exhaust Configurations
16
19
51
62
69
73
75
Cooling Charts
79
86
Glossary
88
Page 2
Page 3
The Solution:
Freightliner Trucks and our engine partners, Detroit Diesel and Cummins Inc., have worked hard to
meet important new clean air mandates, while maintaining maximum fuel efficiency and engine
performance.
The Particulate Matter output guidelines were satisfied with the addition of the aftertreatment device
in 2007. In 2010, Nitrogen Oxide (NOx) levels will be dropped through the introduction of a
second device, the Selective Catalytic Reduction (SCR) catalyst. This is the only way to meet 2010
emissions standards at the tailpipe. Figure 2 outlines the technology progression through emission
Levels - pre- 2007, EPA 2007 and EPA 2010.
Engine with EGR
Particulate Reduction
NOx Reduction
Pre 2007
EPA 2007
EPA 2010
EGR
EGR +
Reduced EGR +
SCR Catalyst
Page 4
1
= Exhaust
3
DEF injected into the
exhaust stream
2
NOx
PM
NH3
4
DEF solution hydrolyzes into
ammonia gas (NH3) which mixes
with the exhaust
H2O N2
5
Ammonia (NH3) and Nitrogen
Oxides (NOx) react in the catalyst
to form Nitrogen and Water
Page 5
In-Cylinder EGR
Less efficient combustion process requires greater cooling
Increased diesel particulate matter (soot)
Increased heat rejection causes the engine to produce more heat
Decreased horsepower for same displacement size engine
Requires increased air flow and cooling capacity
Increased engine complexity with additional turbocharger and EGR cooler
How customers are impacted with in-cylinder EGR?
Decreased fuel efficiency
Potential increase in active regeneration and fuel burned
Increased complexity in turbo chargers, air supply system, pistons and injectors
Decreased engine durability relative to SCR
Page 6
http://www.detroitdiesel.com/emissions/epa2010/
http://truthaboutscr.com/
http://www.factsaboutscr.com/
http://www.truckscr.com/
Page 7
Page 8
Engine
Exhaust
Understep &
Mid Chassis
LG-1
Jan 2010
Cascadia 125 (DD15)
Cascadia 113 (DD13)
Coronado SD (DD15)
Coronado 122 (DD15)
Coronado 132 (DD15)
LG-2
Mar 2010
Cascadia 125 (DD13)
Coronado SD (DD13)
Coronado 122 (DD13)
M2 112 (DD13)
M2 112V (DD13)
LG-3
May 2010
Cascadia 125 (DD16)
Coronado SD (DD16)
Coronado 122 (DD16)
Coronado 132 (DD16)
2V2
Vertical
LG-4
July 2010
Mid-Chassis Mtd
Left Hand Vert Tailpipes
In-cab battery box
2HV
Horiz/Vert
Coronado SD (DD13/15)
Coronado 122 (DD13/15)
Coronado 132 (DD 15)
only in
DD13/15
Switchback
US
Mid-Chassis Mtd
CAS 125 (>500hp)
Coronado SD (>500hp)
Coronado 122 (>500hp)
Coronado 132 (>500hp)
2HV
Horiz/Vert
2HH
Horizontal
Page 9
Engine
Exhaust
Switchback
US
2HH
Horizontal
2V2
2 Box- Vertical
2HH
Crossover
LG-1
Jan 2010
LG-2
Mar 2010
M2 106
LG-3
May 2010
LH B/C
Pillar Vertical
Tailpipes
M2 106
M2 106
RH Mtg
LG-4
July 2010
M2 106
LH Mtg
M2 106
Page 10
Engines
Page 11
Model
M2 106
Medium Duty
M2 106V
Cascadia 113"
Cascadia 125"
Coronado SD
Heavy Duty
Coronado 122"
Coronado 132"
M2 112/112V
ISB
Cummins
ISC
ISX
Target Market
LTL
Regional Distribution
Specialized Hauling
Vocational
Owner Operator
Vocational
Displacement [l]
HP Range [hp]
Torque Range [lb-ft]
Models
12.8
14.8
15.6
350 450
455 560
475 600
1250 1650
Cascadia 113
1550 1850
Cascadia 125
1750 2050
Cascadia 125
Cascadia 125
Coronado SD
Coronado SD
Coronado SD
Coronado 122"
Coronado 122"
Coronado 122"
Coronado 132"
Coronado 132"
M2 112/112V
Target Market
Regional Distribution
Regional Distribution
Specialized Hauling
Vocational
Vocational
Owner Operator
6.7
8.3
14.9
200 325
260 350
400 600
520 750
660 1000
1450-2050
Cascadia 125
M2 106/106V
M2 106/106V
Vocational
Displacement [l]
HP Range [hp]
Torque Range [lb-ft]
Models
Coronado SD
Coronado 122"
Coronado 132"
Page 12
EPA 2010 DD 15
EPA 2010 DD 16
Page 13
RV
Data Code Rated HP HP @ RPM Rated Torque Torque RPM
101-2R4
525
1800
1650
1200
101-2R6
450
1800
1450
1200
101-2R7
600
1800
1850
1200
Page 14
Rated HP
200
220
240
250
260
280
300
325
Rated HP
340
360
Page 15
Exhaust Configurations
Page 16
Engines
Exhaust
Config.
Right Hand
Understep Systems
Vertical Systems
Horizontal Systems
2V2
2HV
DPF
SCR
SCR
DPF
Switchback
2HV
2HH
SCR
SCR
SCR
DPF
Switchback
DPF
DPF
2V2
2HH
DPF
SCR
SCR
DPF
SCR
Crossover
DPF
DPF and SCR in vertical position
Page 17
F&E
Tanker
Bulk
Mixer
Dump
Utility
2V2
2HV
&
Horiz
Horiz Under
UnderIn-line step
Understep
TL/LTL
2V2
Horiz
Crossover
Medium Duty
Heavy Duty
The exhaust configurations are developed with every application in mind. The applications shown
below are projections and the aftertreatment system variants will not be restricted to applications
shown.
Refuse Logging
Plow Plow w/
w/o
P&D
scraper scraper
Bev
School
Bus
Step
Van
RV
Page 18
Exhaust Configurations
Heavy Duty Models
Page 19
The Right Hand (RH) Understep 1-Box solution offers many advantages to customers such as:
Compact/integrated design
Highest fuel efficiency due to low system back pressure
Clear Back of Cab (BOC) solution
Lowest weight Heavy Duty Aftertreatment System (ATS)
Multiple tailpipe offerings
Only dual tailpipe option
Clear Right Hand Power Take Off (PTO) solution
Page 20
ATS Mounting
Plate
Exhaust Inlet
ATS Lower
Mounting casting
ATS outlet
DEF injector
Page 21
Page 22
Page 23
Page 24
Page 25
M2 112/112V MidChassis
1810mm BOC
Page 26
Page 27
Page 28
Note: The BOC to SCR outlet is 1588 mm in Coronado 122 Sleeper Cab (70) SFA with ISX
Page 29
Note: The BOC to SCR outlet is 1587 mm in Coronado 132 Sleeper Cab (70) SFA with ISX
Page 30
Note: The BOC to SCR outlet is 1588 mm in Coronado SD Sleeper Cab (70) with ISX
Page 31
DPF
SCR
Page 32
Sensor Box
SCR
Mounting Cross Brace
(concept only)
Heat/Beauty Shield
FWD
Page 33
1774 mm mid
frame to high
point of doser
1774 mm mid
frame to high
point of doser
Page 34
1774 mm mid
frame to high
point of doser
1774 mm mid
frame to high
point of doser
Page 35
1774 mm mid
frame to high
point of doser
660 mm
300 mm
Outside of Rail
Page 36
SCR
DPF
Page 37
SCR Single
Vertical Variant
Engine out exhaust
DEF Dosing
Unit
DEF Injection
(on SCR inlet)
DTNA designed
intermediate pipe
Page 38
1605 mm
mid frame
to top of
SCR
1605 mm
mid frame
to top of
SCR
Page 39
1605 mm
mid frame
to top of
SCR
1605 mm
mid frame
to top of
SCR
Page 40
1605 mm
mid frame
to top of
SCR
Page 41
SCR
DPF
Page 42
SCR Single
Vertical Variant
Cummins DEF
decomposition reactor
DEF injector
Page 43
1715 mm
mid frame
to top of
SCR
1715 mm
mid frame
to top of
SCR
Page 44
1715 mm
mid frame
to top of
SCR
Page 45
Page 46
Page 47
SCR
DPF
Page 48
Page 49
Exhaust Package: 016-1D2 (RH Inboard Frame Mounted Horizontal DPF and SCR With RH Mounted
Vertical Tailpipe)
Cascadia 125 Sleeper Cab (72) with ISX
Page 50
Exhausts
Medium Duty Models
Page 51
SCR
DPF
Page 52
Daycabs
Ext/Crewcabs
Page 53
460 mm
Center of rail to lowest
point on ATS
25 mm BOC to ATS furthest rear edge
942 mm
ATS Length
BOC
770 mm
Outside of
Rail
Page 54
BOC
Outside of
Rail
665 mm
Page 55
SCR
DPF
Left-hand and Right-hand configurations are available for different markets, e.g. Snow Plows.
RH
LH
Page 56
BOC
Outside of Rail
Page 57
1075 mm
15 mm
Forward
Forward
Page 58
Page 59
1270 mm BOC to
rear face of ATS
Crewcab
BOC
Daycab
BOC
Outside of Rail
330 mm
Page 60
ISB/ISC 2HH-Crossover
Page 61
Page 62
Exhaust Datacodes
Cascadia - DD13/15/16
Data
Code
016-1C1
1-Box Understep
016-1C3
016-1DC
016-1DD
016-1C7
Description
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH Frame
Mounted Vertical Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH
Horizontal Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH
Horizontal Tailpipe Exiting
Forward of Rear Tires
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with LH
Horizontal Tailpipe Exiting
Forward of Rear Tires
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with LH Frame
Mounted Vertical Tailpipe
CAS 113" DC
CAS 125" DC
CAS 113" DC
CAS 125" DC
CAS 113" DC
CAS 125" DC
CAS 113" DC
CAS 125" DC
2V2
RH Inboard Frame
Mounted Horizontal DPF
CAS 125" SC
016-1DB and RH Outboard Frame
Mounted Vertical SCR With (60" & 72" SC only)
Topstack
Launch
Group
2HV
RH Outboard Frame
Model
Top View
3D
Legend: Dark Red: Exhaust System, Green: Battery Box, Yellow: Urea Tank
Ex.
Battery Box
Exhaust System
Urea Tank
Page 63
Exhaust Datacodes
Cascadia - Cummins ISX
2HV
1-US Switchback
Data Code
016-1C1
016-1C3
016-1DB
016-1C9
2HH
016-1D7
016-1D8
016-1D2
Description
Model
Launch
Group
Top View
3D
Legend: Dark Red: Exhaust System, Green: Battery Box, Yellow: Urea Tank, Orange: Fuel
Ex.
Exhaust System
Battery Box
Urea Tank
Fuel Tank
Page 64
Exhaust Datacodes
Coronado & Coronado SD - DD13/15/16
Data Code
016-1C2
016-1C6
016-1DD
1-Box Understep
Launch
Group
1
016-1DC
016-1C4
016-1C5
2V2
Model
Coronado 122 & 132, Coronado SD
Day Cabs and Sleeper Cabs
(not in 34" & 48" SC)
016-1C3
2HV
Description
016-1C0
RH Outboard Frame
Mounted Vertical ATS
Assembly With Topstack
016-1DB
RH Inboard Frame
Mounted Horizontal DPF
Coronado 122 & 132, Coronado SD
and RH Outboard Frame
Mounted Vertical SCR With Sleeper Cabs (only in 48", 58" and 70")
Topstack
Top View
Page 65
Exhaust Datacodes
Coronado & Coronado SD - Cummins ISX
Data Code
1-US Switchback
016-1C3
016-1C2
2HV
016-1C4
016-1DB
016-1C9
2HH
016-1D7
016-1D8
016-1D2
Description
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH
Horizontal Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH B-Pillar
Mounted Vertical Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with Dual Cab
Mounted Vertical Tailpipes
RH Inboard Frame
Mounted Horizontal DPF
and RH Outboard Frame
Mounted Vertical SCR With
Topstack
RH Inboard Frame
Mounted Horizontal DPF
and SC With Horizontal
Tailpipe
RH Inboard Frame
Mounted Horizontal DPF
and SCR With RH
Horizontal Tailpipe Exiting
Forward of Rear Tires
RH Inboard Frame
Mounted Horizontal DPF
and SCR With LH
Horizontal Tailpipe Exiting
Forward of Rear Tires
RH Inboard Frame
Mounted Horizontal DPF
and SCR With RH Mounted
Vertical Tailpipe
Model
Launch
Group
Top View
Page 66
Exhaust Datacodes
M2 112/112V - DD13
Data Code
016-1C3
1-Box Understep
016-1DC
016-1DD
016-1C2
016-1DE
016-1C6
016-1DK
2V2
016-1C0
016-1C8
Description
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH
Horizontal Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH
Horizontal Tailpipe Exiting
Forward of Rear Tires
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with LH
Horizontal Tailpipe Exiting
Forward of Rear Tires
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH B-Pillar
Mounted Vertical Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with RH C-Pillar
Mounted Vertical Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with LH B-Pillar
Mounted Vertical Tailpipe
RH Outboard Under Step
Mounted Horizontal ATS
Assembly with LH C-Pillar
Mounted Vertical Tailpipe
RH Outboard Frame
Mounted Vertical ATS
Assembly With Topstack
LH Outboard Frame
Mounted Vertical ATS
Assembly With Topstack
Model
Launch
Group
M2 112 / 112V
M2 112 / 112V
M2 112 / 112V
M2 112 / 112V DC
M2 112 / 112V
Ext. and Crew Cabs
M2 112 / 112V DC
M2 112 / 112V DC
M2 112 / 112V DC
Top View
3D
Page 67
Exhaust Datacodes
M2 106 (ISB & ISC) and M2 106V (ISC)
Data Code
Model
Launch
Group
M2 106/106V
016-1DC
016-1DD
016-1C3
1-Box Understep
Description
016-1C2
016-1DE
Side View
016-1C6
016-1DK
2V2
016-1C0
LH Outboard Frame
Mounted Vertical ATS
Assembly With Topstack
2 HH Crossover
2HH
016-1C8
016-1C9
016-1DA
RH Inboard Frame
Mounted Horizontal DPF
and SCR With Horizontal
Tailpipe
RH Inboard Frame
Mounted Crossover DPF
and SCR
M2 106 / V
Extended and
Crew Cabs
M2 106 / 106V
Day Cab &
Extended Cabs
M2 106 / 106V
Day Cab &
Extended Cab
M2 106/106V
M2 106/106V
Page 68
Page 69
Immersion heater using engine coolant to heat urea in cold ambient conditions
DEF will be allowed to freeze when the vehicle is non operational in temperatures below 12 F
Vehicle is fully operational when DEF is frozen vehicle operation will heat urea within
prescribed time in order to allow SCR system to operate
DEF is not damaged or destroyed if it is frozen and is fully usable when thawed
All DEF is purged from transfer lines when the vehicle is shutdown
Page 70
Fuel Capacity
6 gal
100 gal
13 gal
200 gal
23 gal
300+ gal
Page 71
Medium Duty:
- DEF tank located aft of rectangular fuel tanks
- All DEF tank sizes available
Page 72
Page 73
Gauge Lamps
DEF Lamp
Legend
DEF Lamp
OFF
50% to 75%
3 green lights
OFF
25% to 50%
2 green lights
OFF
10% to 25%
1 green light
OFF
5% to 10%
1 yellow light
ON SOLID
0% to 5%
1 red light
flashing
FLASHING
Under no circumstances will the engine be shutdown due to running the vehicle out of DEF.
Page 74
DEF
Common Misconceptions
Page 75
Hazards Identification
Urea Solution is not Flammable
Transportation Information
Urea solution is not listed by any US or Canadian transportation
authority as a hazardous material
2. DEF will be difficult to find or purchase FALSE
FACT: OEMs and engine manufacturers are working diligently to ensure DEF will have broad
availability at dealerships, service centers, truck stops and retail outlets. DEF can be purchased in 1
gallon, 2 gallon, 55 gallon drum and 275 gallon IBCs. 275 gallon IBCs will climate controlled, stand
alone dispensing units.
Page 76
Page 77
The DEF gauge indicates the level of DEF in the tank and has a
series of alerts when the tank is running low
7. EPA2010 and EuroV (2008) are the equivalent emissions levels FALSE
FACT: Even in 2013 Europe will not be required to meet the same level of NOx emissions as
North America in 2010
Page 78
Cooling Charts
Page 79
Coronado SD
Coronado 122
Page 80
Coronado SD
Coronado
Page 81
Coronado SD
Coronado
Page 82
Page 83
Coronado
Page 84
Cummins ISC
Page 85
Page 86
25 Fuel Tanks
25.0 in
Glossary
Page 88
GLOSSARY
AfterTreatment Device (ATD): Combination of Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF)
used to meet 2007 EPA emissions standards
Bluetec: Daimlers branded SCR emissions solution
Diesel Exhaust Fluid (DEF): A solution of 32.5% automotive-grade urea and 67.5% purified water used in the SCR
process; also referred to as AUS32
Diesel Oxidation Catalyst (DOC): Part of the 2007 Aftertreament system that converts soot into ash
Diesel Particulate Filter (DPF): Part of the 2007 Aftertreatment system that traps ash
SCR: Selective Catalytic Reduction = A vehicle emissions control technology to reduce diesel engine emissions for
passenger cars, light & heavy duty trucks. Reduces NOx using a reducing agent by converting NOx into nitrogen, water
and tiny amounts of carbon dioxide
SCR Catalyst: EPA 2010 hardware used to convert NOx into Nitrogen and Water
2V2: 2 Box Vertical Aftertreatment System Vertical DPF and Vertical SCR
2HV: Horizontal DPF and Vertical SCR
2HH: Horizontal DPF and Horizontal SCR