Freightliner: new exhausts, no problems

FREIGHTLINER has made a variety of changes in its truck lineup to accommodate the tighter diesel exhaust regulations that took effect this year, many of which are designed specifically to make mounting bodies and equipment on SCR-equipped trucks a hassle-free process.

The company began its Truck Product Conference presentation by showing the array of options available for exhaust system routing. Choose the proper option, and the exhaust system should be out of the way of upfitter installations. The key to the flexibility is the understep aftertreatment systems, Freightliner's Ivan Neblett.

“With the understep packaging, we can take 50 gallons of fuel, six gallons of DEF, two batteries underneath the cab, and get absolutely a clear back-of-cab for any body installation,” Neblett said.

With these components out of the way, the company is better able to provide more flexibility in the ways the exhaust system can be routed. For example, the right-hand outboard frame-mounted vertical aftertreatment system assembly provides the ability to package fuel tanks underneath the right-hand door, making dual fuel applications possible.

Along with a variety of exhaust routing possibilities are multiple diesel-exhaust fluid tanks and locations. Freightliner will offer DEF tanks with capacities of six, 13, and 23 gallons.

“There is flexibility to locate tanks,” he said. “Yes, we're into EPA10, but you can still mount bodies. I hope the conversation now is, ‘It's not a big mystery.’ We still are aware that as these trucks come out of the factory, there may be a need to move components and modify locations.”

Neblett said that tailpipes can be rerouted and that under certain circumstances, with permission of the truck and engine manufacturers, the forward sections of the exhaust system can be modified. DEF tanks can be moved to either framerail according to Freightliner guidelines.

“The main story is that we are EPA '10, we are producing trucks — at this point more than 18,000 trucks with these systems in North America. Emission systems are not an issue now.”

Electrical system updates

Freightliner also has completed EPA2010 M2 Electrical Body Builder Reference Guide. The guide has new content, including: power distribution road map; power net distribution box and positive battery disconnect; high current switch packages; high current switch label options; bulkhead connector details; PTO controls and schematics; hybrid ePTP connections; remote start-stop controls; and VDR prep information.

The body builder and trailer power distribution modules have been relocated from the chassis frame to the cab — on the back wall behind the driver's seat. This protects the electrical components by removing from the harsh environment outside the cab. To retain the ease of use of the power distribution modules, wiring runs out the cab via a factory pass-through to provide current to the body builder connectors are on the frame at the back of the cab and end of the frame.

On module 353, there is a high-amperage vehicle interface lighting output change, with additional outputs (two 20-amp battery outputs and one 20-amp ignition output).

Ignition-controlled extra switches with indicator lights are wired to the PDM with 20-amp circuit relays. Data codes: 329-090 (10 switches), 329-091 (six switches), and 329-092 (eight switches). The customer can order additional switches pre-labeled from the factory.

He said it's important because third-party switches are needed for the dash, it presents a clean and more consistent look and feel of the dashboard, and it eases truck body and equipment integration and presents a “better quality and finish” to the end user.

There are three safety features:

  • Audible warnings — door open without park brake set. This warns drivers not to leave the cab without setting the park brake. Data codes: 275-060 (with door open and ignition key off or accessory position); 275-061 (with door open and all ignition key positions).
  • Audible warnings — exterior regen notification. This notifies the driver when manual regen is required, warns the driver not to leave the cab without setting the park brake, and avoids potential plugging of the DPF filter. Data codes: 275-063 (two-stage electric horn and hazard lamp alert controlled by particulate filter regeneration required status); 275-064 (electric horn warning system for park brake not set with door open and all ignition key positions; and two-stage electric horn and hazard lamp alert control by particulate filter regen required status).
  • Distraction reduction — radio off in reverse. This removes driver distraction while backing up and lowers noise level so the driver can hear warnings. Data codes: 74D-001 (for reverse or PTO engaged); 74D-002 (when vehicle in reverse gear).

The in-cab battery box is available in Cascadia and Coronado/SD day cabs, and with Cummins DD13 and DD15. The design accommodates up to four batteries, provides clean back of cab, frees up 20" of rail space, and is compatible with AGM batteries only.

Allison Optimized is a holistic approach to configuring a vehicle's driveline that delivers optimal performance, durability, fuel efficiency, and driveline protection for specific vocational markets, including Class 8 construction/dump, urban tractor/day cab, heavy haul (80,000 lbs GCVW), and CNG/LNG vehicles. Components optimized: Shift Energy Management (SEM); Load-Based Shift Schedule (LBSS); recommended shift schedules; auto neutral on park brake apply; prognostics; and ease of order/spec process. He said Allison Optimized benefits natural gas vehicles because of improved startability at launch and full power shifts.

He said the pre-wire for customer-installed trailer controller is available in February. It's standard seven-way trailer connector wiring that provides blunt-cut wires behind the dash and wire to the rear of the chassis. Data codes: 296-026 (wired for separate stop/turn, center pin powered through ignition with stop signal pre-wire package); 296-027 (wired for combination stop/turn, center pin powered through ignition with stop signal pre-wire package).

He said air suspension controls became available in November. This option locks specific air pressure in air suspension bags to prevent suspension-leveling valves from exhausting air, and it's actuated with customer input. He said it's important because it eases truck equipment manufacturer body integration by pre-installing all wiring and pneumatic components, and maintains air pressure in the air suspension when outriggers or rail gear are deployed.

Natural gas

Mike Good, product manager, said Daimler Trucks North America has put more than 2000 natural gas units into service, including 328 Sterling SB 113 LNG port tractors; 183 Freightliner M2 112 CNG and LNG trucks and tractors; 540 Freightliner/Sterling LNG and CNG port tractors, LNG and CNG food delivery tractors, CNG regional haul tractors, CNG refuse tractors, CNG sewer tractors, CNG gas utility trucks, and CNG municipal government trucks.

He said there are 35 on order, with quotes out on 800 more.

“All natural gas components are factory-installed and warranteed,” he said. “We install the engines and we install the tanks — the only OEM that does this.”

He said the ISL G natural gas truck, introduced in June 2007, has three-way catalyst aftertreatment, a passive device that is packaged as a muffler and is maintenance-free. Stoichiometric combustion-cooled EGR has the same rated speed as an ISL diesel, 30% more torque at idle, and 5% better fuel economy.

Methane-detection sensors are mounted in the cab, engine compartment, and outside the cab near the fuel tank. They visually and audibly warn the driver of fuel leaks. The NG will ignite when there is a 5%-15% mixture in the air. Asphyxiation can occur when the concentration reaches 21% (a visible vapor cloud) — but that can't occur in unconfined spaces.

He said the payback on the CNG model is 1.2 years, with $14,614 in annual fuel savings versus diesel; and 1.6 years on the LNG model, with $8,250 in annual fuel savings versus diesel.

Also new

Other changes in the Freightliner include:

  • A new 1200-square-inch radiator.
  • An air-intake system that pulls air from under and outside the hood, which helps the stream of air when snow and debris may otherwise constrict air flow.
  • A new headlight system has composite headlights that feature complex reflectors with halogen bulbs for superior lighting performance over the previous sealed beam headlights.
  • Freightliner also retained the front-frame rail extensions with integral FFE, allowing for a constant resistance bending moment from the front of the frame extension to the end of the rail. It is available in 6" and 24" lengths, providing a solid mounting point for pumps, winches, front stabilizers, and snowplows.
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