EPA 2010 ATS and DEF Modification Guide

1Revision A 8 April 2010

Daimler Trucks North AmericaEPA 2010 Exhaust and Aftertreatment System Body Builder Modification Guidelines


Table of Contents

1.0 Introduction

2.0 Applications

3.0 References

4.0 Glossary of Terms - EPA 2010 Emission Systems

5.0 Warnings

6.0 ATS Relocation Guidelines

7.0 Exhaust Tailpipe Modification Guidelines

7.1 Exhaust Tailpipe Size and Material

7.2 Exhaust Tailpipe Clearances to Surrounding Components

7.3 Exhaust Tailpipe Connection to the ATS Outlet

7.3.1 ATS Outlet Connections for Cummins Engines

7.3.2 ATS Outlet Connections for Detroit Diesel Engines

7.4 Exhaust Tailpipe Support

7.5 Exhaust Tailpipe Heat Mitigation Device

7.5.1 Heat Mitigation Device Packaging Guidelines

7.5.2 Heat Mitigation Device Attachment

7.6 Exhaust System Backpressure

7.6.1 Detroit Diesel Backpressure Requirements

7.6.2 Cummins Backpressure Requirements

7.6.3 Exhaust Tailpipe Backpressure Guidelines

8.0 DEF System Modification Guidelines

8.1 System Overview

8.2 DEF System Components

8.3 DEF Tank Assembly Relocation Guidelines

8.3.1 DEF Tank Mounting

8.3.2 DEF Pressure Line

8.3.3 Coolant Supply and Return Lines

8.3.4 Electrical Harness

8.3.5 Air Lines

9.0 Revision History


Daimler Trucks North America has developed the following guidelines to ensure that modifications made to the exhaust and aftertreatment systems for 2010 Freightliner and Western Star trucks are consistent with the requirements of the U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and the engine manufacturers.

In addition to these guidelines, Daimler Trucks North America recommends that body builders review the Freightliner EPA10 Reference Book in order to become more familiar with the operation of EPA 2010 exhaust and aftertreatment systems.

For modifications to an EPA 2010 Freightliner Business Class M2 vehicle, these guidelines should be used in conjunction with the Freightliner Business Class M2 Cab and Chassis Vocational Reference Guide, also known as the EPA 2010 M2 Body Builder Book.

1.0 Introduction

These guidelines apply to EPA 2010 Freightliner and Western Star brand vehicles.

2.0 Applications

Freightliner EPA10 Reference BookJuly 2009 Can be found at www.accessfreightliner.com/toolsservices

Freightliner Business Class M2 Cab and Chassis Vocational Reference GuideOctober 2009 Can be found at www.accessfreightliner.com/toolsservices

Detroit Diesel Corporation Document No: 08 OEM 02EPA2010 Exhaust System Installation Design & Testing Requirements for Detroit Diesel EnginesSeptember 2008

Cummins Application Engineering Bulletin AEB 21.782010 Automotive Aftertreatment Diesel Particulate Filter (DPF) Installation RequirementsMay 21, 2009

Cummins Application Engineering Bulletin AEB 21.79Automotive and Bus Selective Catalytic Reduction Installation RequirementsMay 21, 2009

ISO 22241Diesel Engines NOx Reduction Agent AUS32, International Standard

Daimler Trucks North America technical drawings or specifications referenced in this document can be obtained from DTNA Call Center at 1-800-385-4357

3.0 References


The diagrams and terms presented below provide basic overviews of the EPA 2010 exhaust, aftertreatment and DEF systems. Prior to performing any modifications, Daimler Trucks North America recommends that body builders review the Freight-liner EPA10 Reference Book (see chapter 3) to become more familiar with the operation of EPA 2010 exhaust, aftertreatment and DEF systems.

4.0 Glossary of Terms for EPA10 Emission Systems

EPA 2010CumminsUnder Step Mounted Switchback ATS

EPA 2010Detroit DieselUnder Step Mounted 1-Box ATS

EPA 2010Cummins2 Box Horizontal ATS

Turbo Outlet Piping

1-Box ATS

DEF Tank

Tailpipe

Turbo Outlet Piping

ATS

DEF Tank

Tailpipe

Heat Mitigation Device

DPFSCR

Turbo Outlet Piping

DEF Tank

Heat Mitigation Device

ATSDPFSCR


ACM Aftertreatment Control Module

ATS Aftertreatment System. ATS = DPF + SCR.

DEF Diesel Exhaust Fluid

DEF Tank Storage device for DEF

DOC Diesel Oxidation Catalyst

DPF Diesel Particulate Filter

DTNA Daimler Trucks North America

EPA Environmental Protection Agency

Mitigator Tailpipe exhaust heat mitigation device

PLV Pressure Limiting Valve

SCR Selective Catalyst Reduction

Tailpipe Piping that is downstream of the ATS outlet.

Turbo Outlet Piping Piping that connects the turbo outlet to the ATS inlet.


Failure to follow the installation guidelines and precautions herein may cause personal injury, vehicle damage or damage to the surrounding environment.

Body builder and/or persons performing modifications are responsible for all liability including, but not limited to, that due to stress or failure of components, sanctions from the EPA or CARB due to non-compliance with emissions requirements, and damage or injuries resulting from high temperature exhaust or exhaust system components.

Body builder and/or persons performing modifications are responsible for keeping the vehicle in compliance with applicable laws, noise regulations and safety standards.

Applicable federal, state and local laws also apply.

Freightliner and Western Star warranty requirements may also apply. Please reference warranty prior to performing modifications. Failure to follow guidelines may void entire warranty.

Prior to performing any modifications to the exhaust or aftertreatment system, please review Section 1 of the Freightliner Business Class M2 Cab and Chassis Vocational Reference Guide.

EPA 2010 exhaust systems must be validated as compliant. Any changes to the turbo outlet pipe and/or the after treatment system may bring the system out of compliance. Therefore, changes must be approved by the engine manufacturer and Daimler Trucks North America to meet U.S. 2010 EPA requirements. Any modifications may significantly alter the performance of the system and invalidate the warranty.

The Exhaust Heat Mitigation device effectively reduces the concentration of exhaust gas heat. All exhaust systems with a street level, horizontal, exhaust pipe, must use the mitigator. If installed, the mitigator must remain part of the exhaust piping configuration. Body builders and/or persons modifying the vehicle must ensure that the exhaust gas and exhaust system components are located to protect against damage or injury from high temperatures. Additionally, body builder and/or persons modifying the vehicle must ensure that the final vehicle configuration conforms to all pertinent federal, state, and local requirements, including but not limited to safety, emissions, and noise requirements. See charts for clearances and backpressure guidelines.

Exhaust piping modifications must comply with these guidelines and use proper materials. Proper support must be used to adequately support exhaust piping added.

5.0 Warnings


6.0 ATS Relocation Guidelines

Caution: Use the same pipe size and material as the original tailpipe. Any additional extensions and bends will change the internal gas pressure, which could result in damage to the ATS or other engine components as well as reduction in fuel economy.

.065

5 OD

Aluminized409 Stainless Steel

DDC DD13/15/16Cummins ISXCummins ISB/ISC Engine

.065Wall Thickness

4 ODTailpipe Diameter

Aluminized409 Stainless Steel

Tailpipe Material

100mm 4 inchesRubber/plastic brake line

100mm 4 inchesMetal brake line

100mm 4 inchesElectric harness/heat guard

150mm 6 inchesElectric harness

100mm 4 inchesFuel tank

150mm 6 inchesRubber/plastic fuel line

150mm 6 inchesMetal fuel line

Minimum Clearance (mm)Component

7.1 Exhaust Tailpipe Size and Material

7.2 Exhaust Tailpipe Clearances to Surrounding Components

Relocation of the ATS or modification of the turbo outlet piping is NOT permitted without approval from both Daimler Trucks North America and the engine manufacturer. Requests to relocate the ATS or modify the turbo outlet piping will need to be reviewed on a case by case basis.

7.0 Exhaust Tailpipe Modification Guidelines

These guidelines apply only to the piping that is downstream of the ATS outlet on EPA 2010 Freightliner and Western Star vehicles equipped with an understep or two box horizontally mounted aftertreatment system. If a tailpipe modification is required on a vehicle that is NOT equipped with such aftertreatment system, modification to the exhaust and aftertreatment system must be approved by Daimler Trucks North American and the engine manufacturer.


7.3 Exhaust Tailpipe Connection to the ATS Outlet

The connection between the tailpipe and the ATS outlet varies by engine. Sections 7.3.1 and 7.3.2 present different types of ATS outlet connections available for EPA 2010.

7.3.1 ATS Outlet Connections for Cummins Engines

7.3.2 ATS Outlet Connections for Detroit Diesel Engines

The ATS outlet for Cummins medium and heavy duty engines uses a slip connection that requires no special end treatment for the tailpipe.

The ATS outlet for Detroit Diesel heavy duty engines uses a spherical connection that requires a spherical female flare on the tailpipe.

Tailpipe90 mm (3.5 in) pipe insertion

ATS Outlet

Slip Clamp45-60 lb-ft torque

Tailpipe

ATS Outlet

Spherical Clamp9-11 lb-ft torque

Spherical Gasket

Spherical Female Flare

It is not permissible to use a standard v-band or marmon type flared exhaust pipe in conjunction with the spherical connection on the ATS outlet.


7.4 Exhaust Tailpipe Support

The exhaust tailpipe should be supported so that minimal stress is placed on ATS outlet.

The stress can be due to the weight of the tailpipe hanging on the ATS outlet and/or due to bending loads imposed by the tailpipe. As a general guideline, the distance between tailpipe supports should not exceed 1.2 meters (4 feet). For Business Class M2 vehicles, please refer to the Freightliner Business Class M2 Cab and Chassis Vocational Reference Guide as a guide for locating tailpipe supports.

7.5 Exhaust Tailpipe Heat Mitigation Device

Region greater than 250 Celsius

The exhaust tailpipe heat mitigation device reduces the concentration of exhaust gas heat and is required for all horizontal tailpipe exhaust outlets. The mitigation device has been designed to disperse exhaust gas producing the following thermal distribution representative of active regeneration events for a variety of engine operating conditions including idling speeds.

Temperature zones during regeneration for a 4 tailpipe.

Region greater than 400 Celsius

52.9 mm2.08 in

45.1 mm1.78 in

92.4 mm3.64 in

143.1 mm5.63 in

207.4 mm8.15 in

286.4 mm11.28 in

7.5.1 Heat Mitigation Device Packaging Guidelines

A minimum distance of 150 mm (6 inches) from tailpipe to outer edge of the body is strongly recommended. For exceptional cases where this can not be achieved, the distance should be maximized as much as possible with 50 mm (2 inches) being the minimum allowable distance. Typical exhaust gas temperature distribution zones have been provided for relocation guidance in these exceptional cases.

10

Revision A 8 April 2010

It is highly recommended to never relocate the tailpipe from the position installed by the original vehicle manufacturer. Relocation of a horizontal exhaust tailpipe outlet is acceptable but not recommended by Daimler Trucks North America. Alternative tailpipe designs are available from the Daimler Trucks North America service network that may be more appropriate for specific vehicle applications.

Recommended Minimum: 150 mmAbsolute Minimum: 50 mm

Outer edge of body

Exhaust Gas

Flow Direction

Transverse (300 mm)

5 5

Underside

Transverse (300 mm)

Ground clearance greater than or equal to as-delivered condition

Top Surface

Exhaust Gas

Flow Direction

Top View

Side View

Front View

11


The outlet face should be parallel to the ground within 5 degrees as shown in the front view below.

The tailpipe and heat mitigation device must be no lower than the bottom of the ATS.

Retain the original ground to tailpipe clearance as installed by the vehicle manufacturer.

Never point the exhaust upwards or towards any vehicle components

Vehicle components, e.g. tires, hoses, frame rails etc. should be located no closer than 300 mm from the exhaust tailpipe outlet in the transverse, underside or exhaust gas flow directions.

Vehicle components, e.g. tires, hoses, frame rails etc. should be located no closer than 50 mm from the top surface of the exhaust tailpipe.

7.5.2 Heat Mitigation Device Attachment

The mitigator is made of aluminized 409 stainless steel. Attention should be given to the materials of the connecting pipes for possible galvanic corrosion. Proper weld materials must be used for correct joint creation when using aluminized 409 stainless steel. It is recommended that the tailpipe be secured to another pipe that is connected to the outlet of the ATS using the following:

A marmon style, v-band clamp An exhaust seal clamp Direct welding

It is a violation of federal law to alter the exhaust in such a way that brings the engine/ after treatment system out of compliance. 42 U.S.C. 7522(a)(3)(A)&(B).

7.6 Exhaust System Backpressure

Backpressure is the static pressure measured at the turbo outlet. Backpressure reflects the total pressure imposed on the turbo by the exhaust and aftertreatment system.

Backpressure Unit of Measurement

Pressure = force per unit area. Common units of measure for backpressure are:

in Hg inches of Mercury

kPa kilopascal (1 kPa = 1000 Newtons per square meter)

in H2O inches of Water

psi pounds per square inch

Backpressure Unit Conversion

1 in Hg = 3.39 kPa = 13.60 in H2O = 0.491 psi

0.295 in Hg = 1 kPa = 4.02 in H2O = 0.145 psi

0.074 in Hg = 0.249 kPa = 1 in H2O = 0.036 psi

2.04 in Hg = 6.89 kPa = 27.68 in H2O = 1 psi

12


7.6.1 Detroit Diesel Backpressure Requirements

Detroit Diesel Test Requirements for Backpressure Measurement

Prior to performing any backpressure testing, please contact a Detroit Diesel representative for the most up to date test requirements for backpressure measurement.

The testing requirements shown below were taken from Detroit Diesel Corporation Document No. 08 OEM 02.

The OEM exhaust backpressure contribution will remain the same at 4.0 kPa, identical to Detroit Diesel EPA 2007 specifications.

In order to simplify vehicle validation testing, Detroit Diesel will provide a single backpressure limit as measured at the HC doser outlet elbow provided on the engine performance data sheet. These data sheets can be obtained at www.detroitdiesel.comwith appropriate access privileges. The measurement should be conducted after a parked regeneration with a low mileage (< 5000 mi) ATD.

Pressure should be recorded at full load, rated engine speed per engine performance data sheet to validate exhaust backpressure specification conformance.

Excessive backpressure reduces fuel economy and can potentially damage the turbo-charger. In order to protect the turbocharger from damage, the engine manufacturers have determined a maximum backpressure for each engine and engine rating. The maximum backpressure values are listed the on the engine data sheets.

To determine if an exhaust system is compliant with the engine manufacturers backpressure requirements, the backpressure is measured per the engine manufacturers test procedure and then compared with the maximum backpressurevalue listed on the corresponding engine data sheet. If the measured backpressure value does not exceed the maximum backpressure value, the exhaust system is in compliance.

The testing requirements and maximum backpressure values for both Detroit Diesel and Cummins are presented in Sections 7.6.1 and 7.6.2, respectively.

13


Detroit Diesel Maximum Backpressure Values - per Detroit Diesel engine data sheets

The complete exhaust system with a clean DPF device must meet the allowable exhaust system backpressure limit listed on the engine data sheet for the engine model and rating. The limits for exhaust backpressure in the engine data sheet are when measurements are taken in a 4 inch diameter pipe. When measurements have to be taken in pipe diameters other than 4 inch, then adjustment to the final result will be required.

Exhaust backpressure should be checked at full power at the engine speed which delivers the maximum exhaust gas flow rate as indicated on the data sheet. The restriction measurement must be performed within a maximum of 10,000 miles and 200 hours of operation since the filter was new or undergone ash cleaning. A manual regeneration of the particulate filter must be performed immediately prior to restriction measurement.

The exhaust flow rate in CFM (l/sec) listed on the engine data sheet will assist in sizing exhaust system components. The exhaust backpressure should be checked by running the vehicle at full power output on a chassis dynamometer or long uphill climb.

Cummins Exhaust System Backpressure Requirements

The testing requirements shown below were taken from Cummins AEB 21.78, page 16

7.6.2 Cummins Backpressure Requirements

EngineRating

HP kPa in Hg

475 19.9 5.9500 20.5 6.1535 21.5 6.3550 21.8 6.4600 23.4 6.9

MaximumBack Pressure

DD16

EngineRating

HP kPa in Hg

455 17.2 5.1475 18.5 5.4500 19.9 5.9505 20.0 5.9530 21.8 6.4560 23.9 7.1


DD15EngineRating

HP kPa in Hg

350 17.6 5.2370 18.3 5.4380 18.7 5.5410 19.4 5.7435 20.7 6.1450 21.1 6.2470 22.3 6.6

DD13Maximum

Back Pressure

Values apply only to Detroit Diesel understep mounted ATS.

14


Cummins Testing Requirements for Backpressure Measurement

Prior to performing any backpressure testing, please contact a Cummins representative for the most up to date test requirements for backpressure measurement. The test procedure below was taken from Cummins AEB 21.78, Appendix C, page 22.

1. Perform a non-mission regeneration on the DPF system to ensure it is clean prior to checking exhaust backpressure

2. Connect a manometer or pressure gauge which reads up to 272 in H2O, 20 in Hg, 10 psi. 508 mm Hg or 68 kPa in a straight section of 4 inch diameter exhaust pipe, 3 to 4 pipe diameters downstream of the exhaust engine outlet flange. Turbulence in the exiting gas flow from VGT turbochargers, results in the need to measure exhaust backpressure at this distance from the outlet flange. The port in the exhaust pipe should be smooth and free of burrs to give an accurate pressure reading.

3. Check the Engine Data Sheet to determine the engine speed which delivers the maximum exhaust flow. This is the engine speed which should be used for this test. Testing should be conducted at ambient temperatures between 21 to 38 C (70 to100 F).

4. Run the engine at full power output on a vehicle chassis dynamometer or a long uphill climb at the correct engine speed for at least 10 minutes or until stabilized power output is achieved, and record the exhaust backpressure reading. For industrial engines, load the engine to the speed at which the maximum exhaust flow occurs for at least 10 minutes and record the exhaust backpressure reading.

5. If this testing is done on a long hill climb, it may be necessary to repeat the test in different gears or use the vehicle brakes to achieve the desired engine speed. If testing on road, the hill used must be steep enough that with the engine at full throttle, the vehicle speed is steady or dropping when the exhaust backpressure is recorded, to ensure the engine is at full power output.

6. If engine turbocharger boost pressure is also recorded during this test, the pressure at the turbo compressor outlet can be compared to the Turbo Compressor Outlet Pressure on the Engine Data Sheet to ensure the engine is at full power output. The measured turbocharger boost pressure should be within 75 mm Hg (3 in Hg) of the value on the Engine Data Sheet with the engine at full power.

NOTE: When the exhaust backpressure measurement is taken in a pipe diameter other than 4 inch then the measured values must be adjusted to take into account this condition.

15


Cummins Maximum Backpressure Values - per Cummins engine data sheets

EngineRating

HP kPa in Hg

200 26 7.7220 28 8.4240 31 9.1250 32 9.6260 33 9.9280 34 10.2300 41 12.0325 42 12.5340 50 14.9360 46 13.6


EngineRating

HP kPa in Hg

260/270 31 9.3300 35 10.3

330/350 38 11.3380 40 11.9


EngineRating

HP kPa in Hg

400 26 7.7425 28 8.2450 29 8.6485 30 9.0500 31 9.3525 34 10.0550 36 10.6600 39 11.5


Values apply only to all Cummins ATS configurations

16


7.6.3 Exhaust Tailpipe Backpressure Guidelines

ExhaustTailpipe

ModificationEffect on Backpressure Guidelines & Recommendations

Additionof

straight pipe

Backpressure increase is dependent upon the length of straight pipe added and the roughness of the inside pipe surface.

Avoid pipes with rough inside surfaces.

Additionof

bends

Backpressure for each added bend is dependent upon the bend angle, bend radius, and roughness of the inside pipe surface. Bends impose significantly more backpressure than straight pipe.

Keep number of bends to a minimum.Use large bend radii where possible.Avoid pipes with rough inside surfaces.

Additionof

flex hose

Backpressure increase is dependent upon the length of flex hose added and the straightness of the flex hose. Flex hose imposes significantly more backpressure than straight pipe.

Keep flex hose length to a minimum.Avoid using flex hose for bends.Install flex hose as straight as possible.

Additionof

weld seams

Backpressure increase dependent upon how much weld slag bleeds through the weld seam to the inside surface of the pipe.

Avoid excessive bleed through on weld seams.

Almost all tailpipe modifications will result in increased backpressure.

Please see the table below for guidelines and recommendations for the most common exhaust tailpipe modifications. Using these guidelines and recommendations, the margin between the factory installed exhaust system backpressure and the maximum allowable backpressure is large enough to allow for most common tailpipe modifications.

17


Daimler Trucks North America has developed the following guidelines to allow certain modifications to the DEF systems for 2010 Freightliner and Western Star trucks. These Modifications have to be consistent with the requirements of the U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and the engine manufacturers.

8.0 DEF System Modification Guidelines

DTNA offers 3 DEF tank sizes to optimally cover our customers needs and packaging requirements with 6, 13 and 23 gallon nominal capacity. DEF tank sizes are tied to diesel fuel tank capacity. While it is always possible to use a larger DEF tank than required, it is not permissible to use a smaller DEF tank.

8.1 System Overview

Performance of the DEF System is critical to meeting EPA2010 emission regulations. Not meeting the requirements of DTNA, the engine manufacturers and EPA might bring the vehicle out of compliance.

300+ gal

200 gal

100 gal

Diesel Tank Size (max.)

6,90023 gal

3,90013 gal

1,8006 gal

Range *(miles)

DEF Tank Size

300+ gal

200 gal

100 gal

Diesel Tank Size (max.)

6,90023 gal

3,90013 gal

1,8006 gal

Range *(miles)

DEF Tank Size

* based on 2.5% dosing rate using 2.3:1 DEF to diesel fuel fill ratio

6 gallon

13 gallon

23 gallon

18


The larger tanks share a cage style mounting concept where the tank is enclosed by a carrier bracket and secured with a compression strap while the small tank is sitting on mounting cylinders attached to an L-shape bracket and secured by retainer discs.

Standard location for DEF pumps is the lower inboard side of the DEF tank carrier bracket, on 6 gallon tanks an aft mounted pump is available besides the standard lower inboard mounted one.

Inboard mounted pump on 13 gallon tank

Inboard mounted pump on 6 gallon tank

with cover

aft mounted pump (optional) on 6 gallon tank

DTNA trucks use different DEF dosing systems depending on engine manufacturer. Detroit Diesel engines use an air assisted Hilite dosing system and all Cummins engines use an airless Bosch dosing system.

Hilite air assisted DEF dosing systems require an additional air supply line to the DEF dosing pump which needs to be considered when modifications to the system are planned.

19


Following pictures give an illustration and overview of the DEF system on DTNA vehicles. Be aware that this is an overview only, individual installations and packages might vary.

The DEF system consists of the following components:

8.2 DEF System Components

1

2

3

4

(1) DEF tank assembly(2) Aftertreatment device (ATS)(3) Coolant supply and return line

(from engine)(4) DEF pressure line

(from pump to ATS)(5) Wiring harness - not shown(6) DEF pump cover

5

6

Detroit Diesel 1Box ATS and DEF pressure line shown Cummins understep ATS, DEF pressure line and DEF injector coolant supply and return line shown

4

4

20


(3) Coolant supply and return line(4) DEF pressure line(5) Wiring harness - not shown(7) DEF tank(8) Fill cap(9) DEF supply line(10) DEF return line

7

13

8

3

11

10

9

9

12

12

4

5

13 Gallon DEF tank with Hilite dosing system shown

DEF Tank Assemblies

high coolant routing over the rail shown

from and to engine

14

6 Gallon DEF tank with Bosch dosing system shown

Common coolant connector low routing shown

to ATS

to ATS

5

5

11

4

8

7

9

10

12

13

3

14

3from and to engine

(11) DEF pump(12) DEF tank assembly mounting

brackets (fwd and aft)(13) DEF tank carrier bracket(14) Coolant jumper line(15) Air supply line not shown

515

21


There are several coolant line routings to the DEF tank assembly, depending on DEF tank size, mounting and other packaging considerations. The coolant routing can be either a high routing, over the rail or low routing, under the rail.

High routing over the rail(Bosch system shown)

Low routing under the rail (Bosch system shown)

Coolant lines routed high, over the frame rail

Coolant lines routed low, under the frame rail

DEF Tank Coolant Line Routing

22


DTNA allows the relocation of the complete DEF tank assembly only. This includes the DEF tank and its carrier and mounting bracket, DEF pump and all DEF and coolant lines routed back and forth between pump and tank, see pictures on page 21 for reference.

8.3 DEF Tank Assembly Relocation Guidelines

Relocation of the DEF pump by itself is not authorized by DTNA and could result in vehicle malfunction. Such action might bring the vehicle out of compliance.

EPA2010 DEF system must be validated as compliant. Any changes to DEF tank, dosing system, DEF lines, coolant lines, electrical harnesses and air lines may bring the system out of compliance. Therefore changes must be approved by the engine manufacturer and Daimler Trucks North America to meet U.S. 2010 EPA requirements.

DTNA allows the relocation of the complete DEF tank assembly only. The body builder and/or person modifying the vehicle have the responsibility to find an adequate location for the DEF tank assembly on the vehicle, considering but not limited to the following aspects:

y Temperature exposure of DEF and components of DEF tank assemblyy Packaging clearances to other chassis or vehicle componentsy Environmental exposure, e.g. wheel spray and road debrisy Ergonomic considerations for tank fillingy Accidental DEF spillage during tank fill; impact on surrounding componentsy Structural integrity of mounting and possible load inputs into DEF tank

assembly

The DEF tank assembly must be securely mounted using the existing DEF tank assembly mounting brackets and at least four 5/8 fasteners (grade 8 minimum) of appropriate length, two for each bracket on 13 and 23 gallon installations and four per bracket on 6 gallon installations.

Detailed information regarding the hole pattern required to mount the DEF tanks can be found on DTNA drilling diagram D15-25099.

8.3.1 DEF Tank Mounting

When relocating the DEF tank assembly, the body builder and/or persons modifying the location of the DEF tank assembly must be considerate of the characteristics and material properties of DEF. Possible accidental spillage during the tank fill process as well as temperature impact of adjacent components must guide an appropriate DEF tank location modification.

Relocating the DEF tank assembly affects the following areas:

y DEF Tank Mountingy DEF Pressure Liney Coolant Supply and Return Linesy Electrical Harnessy Air Lines

23


Complete DEF tank assembly (shown in grey)

DEF tank assembly mounting brackets

DEF tank assembly mounting fasteners

Since DTNA has no visibility regarding the possible vehicle structure the DEF tank assembly will get mounted onto, body builder and/or persons modifying the attachment of the DEF tank assembly have sole responsibility for mounting the DEF tank assembly, assuring mounting integrity and preventing structural damage to the DEF tank assembly under all vehicle operating conditions.

Additionally, body builder and/or persons modifying the vehicle must ensure that the final vehicle configuration conforms to all pertinent federal, state and local requirements, including but not limited to safety and emissions requirements.

DTNA has validated the structural integrity of the DEF tank assembly mounting for the location provided by the OEM.

For structural reasons, it is recommended to mount the DEF tank assembly to the chassis, however, it is permissible to relocate the DEF tank assembly to an alternative, adequate mounting structure such as a vertical stanchion, body structure or similar as long as the height difference between DEF pump and DEF doser on the aftertreatment device does not exceed 1 meter, see diagram below.

DEF tank assembly Aftertreatment

Device

DEF Doser

DEF Pump

DEF Pump Level

DEF Doser LevelX

Height Difference Requirement X: -1 m < X < +1 m

DEF Pressure Line

24


Relocating the DEF tank assembly requires a revised DEF pressure line connecting the DEF pump to the DEF doser on the ATS.

This DEF pressure line is electrically heated and the available power together with hydraulic limitations determine the maximum line length.

8.3.2 DEF Pressure Line

Engine Ma nufa c ture r

Dosing S yste m

Numbe r of Ele c tric a l

Ports

Cummins Bosch 1

2.6 m using 1 port

5.0 m using 2 portsDetroit Diesel Hilite 2

Ma ximum DEF P re ssure Line Le ngth

3.8 m

Once a new location for the DEF tank assembly is found, the appropriate line length needs to be measured. Following the routing path of the DEF pressure line, the correct DEF pressure line needs to be ordered from DTNA.

DEF pressure lines are typically available in 200 mm increments, see chart below.

Detroit Diesel Cummins

04-28841-100 1000 X X 04-28841-120 1200 X X 04-28841-140 1400 X X 04-28841-160 1600 X X 04-28841-180 1800 X X 04-28841-200 2000 X X 04-28841-220 2200 X X 04-28841-240 2400 X X 04-28841-260 2600 X X

04-28847-280 2800 X 04-28847-300 3000 X 04-28847-320 3200 X 04-28847-340 3400 X 04-28847-360 3600 X 04-28847-380 3800 X

04-28872-280 2800 X 04-28872-300 3000 X 04-28872-320 3200 X 04-28872-380 3800 X 04-28872-400 4000 X 04-28872-420 4200 X 04-28872-440 4400 X 04-28872-460 4600 X 04-28872-480 4800 X 04-28872-500 5000 X

Compatability

Detroit Diesel/Cummins

Standard DEF Pressure Line 2600 mm

Cummins Long DEF

Pressure Line > 2600 mm

Detroit Diesel Long DEF

Pressure Line2 Electircal ports

> 2600 mm

Part Number Length[mm] Comment

25


Routing of the DEF pressure line needs to be done with great care to assure functionality and durability of the component and the DEF system.

y Follow engine manufacturers recommendation, see chapter 3 References.y Avoid DEF line exposure to high temperature items, maximum temperature

exposure of DEF line should be less than 50C (122F) and not exceed 70C (158F) at any point. y Minimum bend radius for DEF pressure line is 80mm.y When supporting line, do not choke or crush DEF line.y Do not run DEF line over sharp edges or abrasive surfaces that could damage liney Depending on the installation and the engine manufacturer's guidelines, the

routing of the DEF line should be executed in a way where the line forms a trap or low point close to the DEF doser. This is to ensure any residual fluid remaining in the line after the purge cycle does not reach the DEF doser. y DEF line needs to be supported in a way to eliminate any harmful vibrations.y DEF lines need to be routed in a direct way from the DEF pump to the doser

without any extra loops and any large unsupported sections that could be caught and torn off.

It is not permissible to modify any DEF lines, such as cutting line, attaching different connectors, opening convolute, removing retainer clips etc.

Modifying DEF lines or using other DEF lines than authorized by DTNA could result in component failure, vehicle malfunction and might bring the vehicle out of compliance.

If the vehicle equipped with a Detroit Diesel engine was built utilizing a single electrical port for power supply of the DEF pressure line (line length less than 2.6m) but the desired modification requires a DEF pressure line length of more than 2.6m (therefore 2 electrical ports are needed), a new wiring harness must be ordered from DTNA.

See chapter 8.3.4 Electrical Harness.

26


When the DEF tank assembly is being relocated, the coolant supply and return lines to the tank assembly need to be modified as well.

Depending on the engine manufacturer and the DEF dosing system, the layouts for the coolant systems are different:

5.3.3 Coolant Supply and Return Lines

DDC engines withHilite DEF dosing system

- Coolant heated DEF tank and pump- No cooling for injector required

CUM engines withBosch DEF dosing system

- Coolant heated DEF tank- Injector cooled by engine coolant

Area of coolant line allowed for modification

Area of coolant line NOTallowed for modification (DEF injector coolant line)

Modifications to the DEF injector coolant line are not allowed.

Heater hose used for coolant line modifications must be of the same inside diameter as lines installed by DTNA and meet the requirements of SAE J20R3 Type EC Class D-1, see DTNA part number 48-25927 for reference, and suitable for use on commercial vehicles.

Since the coolant flow thru the DEF system components is directional, all modifications must assure that the coolant flow direction is not reversed at any point.

All coolant lines must be properly routed and secured as well as protected from excessive heat.

27


The coolant plumbing is sensitive to flow direction as well as flow restriction and, in case of Bosch, flow balancing between the tank and injector branch.

It is not permissible to add any other coolant circuits to the DEF coolant supply and return lines.

If the DEF tank coolant line modification significantly exceeds line length and line routing complexity of the factory installed routing, the coolant system needs to be validated per engine manufacturers recommendations to assure system compliance.

Relocating the DEF tank assembly could require increasing length of the wiring harness connecting the DEF tank assembly to the main ACM harness.

The wiring harnesses are different between the Hilite and Bosch DEF dosing system.

8.3.4 Electrical Harness

DDC engines withHilite DEF dosing system

CUM engines withBosch DEF dosing system

Since excess length of the wiring harness can easily be coiled up to adjust for different length requirements, a maximum length wiring harness is available from DTNA to replace the factory installed harness and to cover any modified locations for the DEF tank assembly.

While the single electrical connector port on the ACM from Cummins allows a maximum DEF pressure line of 3.8 meters, an electrical harness of 5.3 meters should connect to any location of the DEF tank assembly within this range.

28


On Detroit Diesel applications two electrical connectors are available at the ACM allowing, if both connectors are used, a maximum DEF pressure line length of 6.5 meters. In order to connect to any location of the DEF tank assembly within this range an electrical harness of 6.5 meters is required.

Depending on the default factory vehicle configuration and the desired DEF tank assembly modification, using both electrical connectors for heating the DEF pressure line requires a reconfiguration of the ACM which can be done at any Detroit Diesel distributor. The ACM programming has to be changed from 3 DEF line heater setting (supply, return, 1 pressure line) to 4 DEF line heaters (supply, return, 2 pressure lines).

Below chart provides an overview and guidance on how to select the correct harness:

Engine Manufacturer

Dosing System

Number of Electrical

Ports

DEF Tank Size and Configuration

Harness Part Number

Harness Length

13, 23 gallon A06-72614-209

6 gallon inboard DEF pump A06-76323-209

6 gallon aft mounted DEF pump A06-77834-209

13, 23 gallon A06-75734-162

6 gallon inboard DEF pump A06-76450-162

13, 23 gallon A06-76379-256

6 gallon inboard DEF pump A06-XXXXX-256

2HiliteDetroit Diesel

4.1 m

6.5 m

5.3 m3.8 m1Bosch

Maximum DEF Pressure Line Length

Cummins

2.6 musing 1

DEF line heater port

5.0 musing 2

DEF line heater ports

All coolant lines must be properly routed and secured as well as protected from excessive heat and exposure to the elements (road debris, wheel spray, etc.).

As the location of the DEF tank assembly with a Hilite DEF dosing systems is being modified, length and routing of the air line providing compressed air to the Hilite DEF pump also needs to be adjusted.

Air to the Hilite DEF pump is supplied from the PLV (Pressure Limiting Valve) via air line, see DTNA specification 48-25855-009.

In case of the DEF tank assembly is moving closer to the PLV, any excess of air line has to be trimmed off and the air line has to be pushed back into the fitting.

Should the distance between the DEF tank assembly and the PLV increase, the complete air line between Hilite DEF pump and PLV must be replaced with an air line of appropriate length per above specification or equivalent.

8.3.5 Air Lines (Hilite System only)

29


DEF pump air supply line

Splicing in air line(s) is not permissible. The air line connecting PLV to DEF pump must be single piece.

The air line must be properly routed and secured as well as protected from excessive heat. It has to be ensured that air lines do not rub on any metal components that could damage the lines. Cable ties can be used to support lines.

30


04/08/10ReimannSpelling correction, final adjustmentsmultipleA

03/31/10ReimannInitial Release

DateByDescriptionPageRev

9.0 Revision History

EPA 2010 ATS and DEF Modification Guide

Documents

exhaust tailpipe support7

exhaust tailpipe size

exhaust tailpipe connection

exhaust tailpipe clearances

exhaust system backpressure7

def system components8

operation of epa

detroit diesel engines7