Trainers Update Meeting

2012 and 2013 Base Engine Changes

Shawn Hinson
O tli d Changes
Outlined Ch for
f 2012
 NAFTA MEASURE JAN – JUNE 2011

•(1 – DD15/DD16) FM New Ring Pack CKS 36/38

•(1 – All) Liner O-ring Material Change
•(4 – All) Fuel pump Nut Change in Material

•(1- All) Double forging rocker supports

•(1 – DD13) Exh. valves on brake side: new material •(2 – All) EGR Valve Stud Bolt (Warrantee Repair Reduction)
•(1 – DD15) Crankshaft with only 4 counterweights •(1 – All) 4 MM Jake Operation - Piston/ Camshaft change
•(4- All) Phase 3 FFM with Pressure Sensor •(1 – All) Rocker arms intake: Delete one

JAN FEB MAR APR MAY JUN

2011
JAN FEB MAR APR MAY JUN

•(4 – All) Software / Fuel Maps Update 7.6/8.6

•(3 – All) Suction Manifold Plastic Solution

•(3 – All) Oil Pan Change Drain Plug to Square Drive
•(1 - All) cylinder Head Gasket Improvement
O h d Ch
Overhead Changes

Training Department Daimler Trucks | 4

I t k R
Intake Rocker
k A Arm “D
“Delete
l t OOne””
N Oil Pan
New P Drain
D i Plug
Pl

½ Inch Square Drive with

Captured
p Washer
 NAFTA MEASURE ** July – Dec 2011

•(2 – DD13) V-Pod Replace Stud with Stud Bolt

•(1 – All) Change to plastic rocker arm spacers

•(2 – DD15/DD16) EGR Cooler Quality improvement

•(2 – All) Electrical actuator: Supplier Change to sonceboz (SBZ)

JUL AUG SEP OCT NOV DEC

2011
JUL AUG SEP OCT NOV DEC

•(3 – DD13) Oil Pan Gasket Material changes

•(1 – All) Piston Pin Cir Clip - Material Change
•(4 – All) Fuel Pump Gear (Noise Reduction)
•(1- All) Front Crank Seal Design Improvement •(1 – DD13) Cylinder head gasket 12.8l, stainless steel
•(2 – All) Boost air pipe cold: change material to plastic
F l pump d
Fuel drive
i gear change
h
A4720770414 A4710770314
A4720770514 A4710770414

Ad
Advances pump timing
ti i 72 d
degrees
DD15 SBZ Actuator
DD13 SBZ Actuator
 NAFTA MEASURE 2012

•(4 - All) Model Year Change Over DD13/DD15 (Software Only)

•(1 – All) Ribbed Flywheel

•(4 – All) Wire harness with XPE

insulation

•(1 – All) Idler Gear 1 & 3 Reduce Weight

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

2012
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

•(1 – All ) Camshafthousing Assembly - AT

Change Tier 2 Supplier

Projects
machined holes 10x

Idler 3 Old

Idler 1 New

forged holes

Idler 3 New forged holes

O tli d Changes
Outlined Ch for
f 2013
A
Agenda
d

1 2013 DDC Engine/Aftertreatment/OBD

E i /Aft t t t/OBD P
Program C
Content
t t & Ti
Timing
i

2 2013 Engine Changes

3 2013 OBD and Electrical/Electronic Changes

4 2013 Customer Demo Program

2013 Program
P Includes:
I l d
DD15 Asymmetric Turbo Engine Offereing for EPA10/OBD13 Certified Markets
(US/Canada)
Minor DD13 and DD16 Engine Changes from MY 2012 Content
Shifting of DD15 Top 2 Ratings to DD16
Improved Fuel Economy For DD15 Engine
GATS Aftertreatment with Liquid Only DEF Systems For All Existing Engines and
GATS+
Vehicles
ODB 2013 for All Engines
MCM/ACM 2.1 Engine and ATS Electronic Control Modules
CPC4 Module
A
Agenda
d

1 2013 DDC E
Engine/Aftertreatment/OBD
i /Aft t t t/OBD P
Program C
Content
t t & Ti
Timing
i

2 2013 Engine Changes

3 2013 OBD and Electrical/Electronic Changes

4 2013 Customer Demo Program

g
DD13 2013 E
Engine
i Program
P
Time - SoP Engine Dec. 2012
DD13 E
Engine
i ChChanges
Cost - No Anticipated Change 1. OBD Application
2. MCM2.1 and CPC4
Q li
Quality
Performance - No Anticipated Change
Impact
p to DTNA
Reliability - No Anticipated Change
1. Same as DD15
Weight - No Anticipated Change
2. Covered in EE Section
NVH - No Anticipated
p Change
g
Service - No Anticipated Change

OBD – Applied to All Ratings/Applications

Ratings – No Anticipated Change
DD13 2013 Ratings
R ti
2010 MY 2013 MY
DD13 Ratings DD13 Ratings
Available with 1Box Sm or 2Box ATS Available with 1Box Sm or 2Box ATS

DD13 2013 DD13 2013

HP Torque DTNA Code HP Torque DTNA Code
370 1250 101-22TC 370 1250 101-22TC
350 1350 101-2T? 350 1350 101-2T?
380 1350 101-2TX 380 1350 101-2TX
380 1450 101-2TD 380 1450 101-2TD
410 1450 101-2TY 410 1450 101-2TY
410 1550 101-2TE 410 1550 101-2TE
435 1550 101-2TF 435 1550 101-2TF
450 1550 101-2TO 450 1550 101-2TO
410 1650 101-2TG 410 1650 101-2TG
450 1650 101-2T1 450 1650 101-2T1
470 1650 101-2TH
101 2TH 470 1650 101-2TH
101 2TH
1350 1350
380 101-2TJ 380 101-2TJ
1550 1550
1450 1450
410 101-2TK 410 101-2TK
1650 1650

No Ratings Changes Currently Planned

DD15 2013 E
Engine
i Program
P

Time
 SoP Engine Dec. 2012

Quality • Quality
Weight
Performance  30kg Weight Reduction
 4%1) better in Fuel Economy compared to NVH
DD15 EPA10 engine  NVH Level equal/better DD15 EEPA10
 Remains Benchmark in Fuel Efficiency Service
and Cost of Operation  Maintenance intervals equal/better DD15
 Top Rating 505 bhp2) /1750 ft*lb EPA10
 Torque Response and Vehicle Acceleration  Cost of Repair and Serviceability equal/better
on/off Grade equal/better •Packaging
 Brake Performance equal/better  Engine/Vehicle Transfer Point will change
Reliability similar to DD13; additional necessary
intermediate exhaust pipe will be part of vehicle
 B50 Life equal/better DD15 EPA10 (1.2M miles) BoM
1) with regulated water pump as standard
2) In combination with ATS medium 1-box (1_US-EM13)
DD15 2013 Engine Content
DD15 Engine Changes Impact to DTNA
1
1. Asymmetrical Turbocharger 1
1. None
2. Exhaust Pipe 2. Vehicle Exhaust Connection Similar to DD13
3. Compressor Inlet Elbow with Temp. 3. Inlet Elbow Supplied by DDC, Engine Mounted,
Sensor Availability of Ambient Temp Measurement
4. Boost Air Outlet Connections 4. New Boost Air Pipe(s) to CAC
5. Regulated Water Pump 5. Verification of VS Fan Control Compatibility
6. Slight Engine Out NOx Increase 6. Slight DEF Increase, Tank Resizing Not
Anticipated
7. Friction and Oil Consumption Optimized
Piston (Still under review) 7. None
8. V140 EGR cooler element 8. None
9. Smaller Oil Pump (DD13) 9. None
10. Max Rating Capped at 505 BHP/1750 10. Radiator Size Reduction, Shift to DD16 for Some
Ft-Lbs Customers
11. 4% Fuel Economy Improvement 11. Competitive Advantage
12. MCM2.1 & CPC4 12. Covered in EE Section
FFriction
i ti and d Oil C
Consumption
ti Optimized
O ti i d Piston
Pi t
(Still under review) Carbon Scraper Ring
V i bl Speed
Variable S dWWater
t Pump
P
•The addition of a customer optional variable
speed water pump to improve fuel economy
economy.
•Pre-investigation has shown this design to
provide approximately a 0.7-1.3% fuel economy
improvement.
•Pump design would incorporate a viscous
clutch.
clutch
•Release is planned for 8/1/2011.

Hardware
•Behr
B h water pump
•New pulley and belt
•Pump
P wiring
ii
DD15 2013 Ratings
2010 MY 2013 MY
DD15 Ratings DD15 Ratings
Available w 1Box or 2Box ATS Available w 1Box Sm or 2Box ATS
DD15 2011 1US Small ATS Package DD15 2013 1US Small ATS Package
HP Torque DTNA Code HP Torque DTNA Code
455 1550 101 2HD
101-2HD 455 1550 101-2HD
101 2HD
475 1550 475 1550
455 1650 101-2JX 455 1650 101-2JX
475 1650 101-2JY 475 1650 101-2JY
475 1650 475 1650
101-2MR 101-2MR
101 2MR
505 1650 505 1650
455 1650 101-2JX 455 1650 101-2JX
505 1650 101-2JO 505 1650 101-2JO
455 1550 455 1550
101-2J4 101-2J4
455 1750 455 1750
475 1650
101-New
475 1850
475 1850 101-New
530 1850 101-New
500 1850 101-New
560 1850 101-New

In 2013 Ratings Above 505 HP or 1750 Ft-Lb Shift to DD16

DD15 2013 H
Hott Sid
Side Ch
Changed
dPParts
t
Exhaust manifold center
EGR Valve
& Hot Pipe

EGR Actuator
& Mounting
Bracket

Exhaust Pipe Charge Air Hot

Outlet Elbow

Turbocharger
DPM2 HC Doser

Support bracket
turbocharger
Turbocharger
Engine wiring
Crankcase with new bosses oil lines
harness
24
DD15 2013 New
N H Heatshields
t hi ld

A 472 140 07 34, Existing

A 472 140 08 34, New

A 472 090 10 34
34, New
A 472 140 09 34, New
DD15 2013 DPM2 HC-Doser
HC D

A472 070 0355 DPM2

Metering Unit

A472 200 0951

Coolant Return Line

A472 078 0841

P-Clip (2x)
HMN 000 997 A0 00
Adapter (2x)

A 004 997 25 71
Adapter A472 142 3204
Exhaust pipe

HMN472 200 5252

Coolant Supply Line
A472 200 0851
HMN 472 078 0202 Coolant Line
Fuel Line
DD15 2013 EGR System
S t

New EGR Pull Rod A470 140 03 80 Hot

EGR Pipe
p with EGR
Valve

A 470 150 00 94
Sonceboz EGR
Actuator

HMN 472 142 07 40

Interim Bracket for
EGR Actuator
 V hi l IInterface
DD15 2013 Vehicle t f Ch
Changes

A472 203 0840 Strut

Rod Bracket Vehicle Strut Rod

Air Intake Elbow with

Temp. Sensor Boss

A472 098 2107

Charge Air Pipe Hot
DD16 2013 E
Engine
i Program
P
Time - SoP Engine Dec. 2012
DD16 Engine Changes
Cost - No Anticipated Change
1. OBD Application
Quality
2
2. DD15 Ratings Transfer
 Performance - No Anticipated Change
3. MCM2.1 and CPC4
 Reliability - No Anticipated Change

 Weight - No Anticipated Change

Impact to DTNA
 NVH - No Anticipated Change
1. Same as DD15
 Service - No Anticipated Change
2
2. New D
N Data
t CCodes,
d R
Revised
i d
OBD – Applied to All Ratings/Applications Sales/Marketing Approach.
Ratings – Absorption of DD15 Ratings above 505 3. Covered in EE Section
HP and
d 1750 Ft
Ft-Lb
Lb
DD16 2013 Ratings
R ti
2010 MY 2013 MY
DD16 Ratings DD16 Ratings
Available with 1Box Lg ATS Available with 1Box Lg ATS
DD16 2013 1US Large ATS Package DD16 2013 1US Large ATS Package
HP Torque DTNA Code HP Torque DTNA Code
475 1750 101 2RW
101-2RW 475 1750 101 2RW
101-2RW
500 1750 101-2RX 500 1750 101-2RX
535 1750 101-2RY 535 1750 101-2RY
500 1850 101-2NK 500 1850 101-2NK
550 1850 101-2NM 550 1850 101-2NM
600 1850 101-2NN 600 1850 101-2NN
475 1750 475 1750
101-2TA 101-2TA
475 1950 475 1950
500 1850 500 1850
101-2TB 101-2TB
500 2050 500 2050
500 2050 101-2R0 500 2050 101-2R0
550 2050 101-2R9 550 2050 101-2R9
600 2050 101-2NP 600 2050 101-2NP

475 1650
475 1850
101-New
101 New Ratings Shifted
475 1850 101-New from DD15
530 1850 101-New
500 1850 101-New
560 1850 101-New

Elimination of Ratings Overlap with DD15 Should be Considered with DD15 Ratings Shifts
A
Agenda
d

1 2013 DDC E
Engine/Aftertreatment/OBD
i /Aft t t t/OBD P
Program C
Content
t t & Ti
Timing
i

2 2013 Engine Changes

3 2013 OBD and Electrical/Electronic Changes

4 2013 Customer Demo Program

g
 OBD L
Legislative
i l ti Requirement
R i t Changes
Ch 2010 to
t 2013
Topic NAFTA OBD 2010 Requirements NAFTA OBD 2013 Requirements
One engine family (14
(14.8l)
8l) requires OBD certification All engines families require OBD certification -
Product scope – only one rating (fleet rating) requires certification one rating for each engine family requires
demonstration certification demonstration
Emission threshold Certify major emissions threshold monitors to 2.5 Certify major emissions threshold monitors to 2.0
monitoring times emissions threshold limit times emissions threshold limit

Compliance of Compliance demonstration of 32 major monitors Compliance demonstration of 6 additional monitors

monitors required required (38 monitors total)

C
Communication
i i Required OBD diagnostics information communicated Standardized J1939 diagnostics communication
acceptable in a Daimler proprietary protocol format required (Daimler proprietary format no longer
protocol (UDS) acceptable)

Performance ratio Performance ratio only required to be tracked and Financial liability for performance ratio
p
reported requirements
q not met
requirements
i

Reporting n/a Increased reporting requirements

System aging No correlation between accelerated and real life Correlation between accelerated aging and real life
system aging required system aging required

Vehicle evaluation Production vehicle evaluation on one production Production vehicle evaluation potentially on x>1
vehicle required production vehicles required
Production vehicle No production vehicle communication Production vehicle communication standardization
standardization testing testing required
testing

Penalties No penalty for deficiencies Pay for deficiencies.

Electronics Hardware Changes for MY2013
1. CPC4 ((Common Powertrain Controller – cab mount))
2. MCM2.1 (Motor Control Module – engine mount)
3. Turbo Compressor Inlet Temperature Sensor on DD15
4
4. EGR Delta-P
Delta P Sensor Supplier Change
5. Engine Harness
6. ACM2.1-EVO (Aftertreatment Control Module – chassis mount)
7. Aftertreatment Harness
8. Powertrain CAN Architecture
9. ECU Flashing Methodology and Time
MY2013 E/E Changes
Ch - CPC4
Description of Change:
Replace CPC2+ 2.0 with CPC4
Plug-in compatible with CPC2+
P/T
/ CAN bus increase to 667 KBaud

Reason for Change:

Microcontroller upgrade to 32-bit, 120MHz, 2MB Flash
DDC Hardware Affected
Provides for future enhancements
CPC4
Software
Variants Affected:
All vehicle configurations
DTNA Hardware Affected
• Electrical Harness – star point
connection required for CAN bus
• Electrical Connectors – no change
MY2013 E/E Changes
Ch - MCM 2.1
21

Description
p of Change:
g
Replace MCM 2.0 with MCM 2.1
Internal Changes

Reason for Change:

Increase Memory (2MB to 4MB)
Increase EEPROM (16K to 32K)
DDC Hardware Affected
Increase starter output capability to drive IMS
MCM
Support P/T CAN change to 667 KBaud
Software
Add Spare Input for Future Expansion
C
Common Gl
Global
b lBBoott Code
C d DTNA Hardware Affected
• Electrical Harness – none
Variants Affected: • Electrical Connectors – none

All Engine Configurations

MY2013 E/E Changes
Ch - Compressor
C Inlet
I l t Temp
T Sensor
S

Description of Change:
Add temperature sensor on inlet elbow

Reason for Change:

Turbo protection

Variants Affected:
DDC Hardware Affected
DD15 AT onlyy
Air inlet
Temperature Sensor

DTNA Hardware Affected

• Electrical Harness – None
• Electrical Connectors – None
MY2013 E/E Changes
Ch - EGR Delta-P
D lt P Sensor
S

Description of Change:
Change supplier to Sensata

Reason for Change:

Lower cost / improved quality

Variants Affected: DDC Hardware Affected

All Engine
g configurations
g Engine harness,
harness venturi (Bolt Size Change)
Pressure Sensor

DTNA Hardware
H d Affected
Aff d
• Electrical Harness – None
• Electrical Connectors – None
MY2013 E/E Changes
Ch - Engine
E i Harness
H

Description of Change:
Add connections for T1 sensor
Modify connections to EGR delta-P sensor
Modify for DPM2 doser block
Modify for Asymmetrical Turbo on DD15

Reason for Change:

Adapt
p to MY2013 engine
g changes
g DDC Hardware Affected
All engine harnesses
Variants Affected:
All Engine Configurations DTNA Hardware Affected
• Electrical Harness – none
• Electrical Connectors – none
MY2013 El
Electronics
t i H Hardware
d Summary
S
MY2013 P
Powertrain
t i CAN A
Architecture
hit t
Diagnostic
Connector
Description
p of Change:
g
J1939 Vehicle Link (250K, 29-bit)
•Powertrain CAN baud rate increase
from 500K to 667K

VCAN)
•Available memory increase in CPC4,
J1587 Vehicle Link
MCM2.1 and ACM2.1
(V

(ECAN)
CPC4
5V, 667K, 29-bit)

5V CAN (500K, 29-bit) Engineering CAN (CAN2)

((CAN 1))
5V CAN (500K,
(500K 29-bit)
29 bit) EGR V
Valve
l CAN (CAN3)
wertrain” CAN (5

MCM2.1
“Pow

5V CAN (500K, 29-bit) Engineering CAN (CAN2)

MISC (CAN 1) 5V CAN (250K, 29-bit) NOx/UQS Sensor CAN (CAN4)

ACM2.1
Controllers
A
Agenda
d

1 2013 DDC E
Engine/Aftertreatment/OBD
i /Aft t t t/OBD P
Program C
Content
t t & Ti
Timing
i

2 2013 Engine Changes

3 2013 OBD and Electrical/Electronic Changes

4 2013 Customer Demo Program

 xCM2.1

MY2013 C
Customer
t Demo
D Program
P Proposal
P l
•20+ Trucks
•All DD15 Powered
•Initial Trucks with 1Box ATS, Last Batch with 2Box ATS units
•12 Months Support Once in Operation
•Update to Certified Engine, ATS, and Vehicle Configuration in 2013
g Builds in Late 2011 thru Q2 2012
•Engine
•Vehicle Builds in Q1 and Q2 2012, Initial Builds Through Corp 7, Final Builds
Through Truck Plants
•1
1stt Vehicles
V hi l iin Customer
C Operation
O i Starting
S i M Marchh 2012
•Customer Pays Basic Truck Price for EPA 2010 Engine/ATS
Vehicle Shakeout Through Corp 12 in Portland Prior to Customer Delivery
•Vehicle
•Technician training being discussed.
 Q ti ?
Questions?

Training Department Daimler Trucks | 44