HDE 14.8 CV-DS NVH PLAN EV ARNOLD, ERIC LEITZINGER, BRYAN UNDERWOOD SUSTAINING ENG‘G & NVH 25 OCTOBER 2006

14.8L HDE NVH TOPICS & OBJECTIVES 25 OCT 2006 NVH METHODOLOGY PRESENTATION ENGINE COMPONENT STRUCTURAL VIBRATION Insure Structural Integrity (Durability) Define Excitation that Creates Sound BYSTANDER SOUND LEVEL (*) Meet Regulatory Requirements Achieve Product Acoustical Performance Goals ENGINE MOUNT VIBRATION LEVEL (*) Minimize Engine Vibration Input into Vehicle Structure TRUCK CABIN SOUND AND VIBRATION (*) Minimize Operator Vibration Fatigue Steering Wheel Seat Minimize Cabin Sound Level Maximize Sound Quality (*) ENGINE IS A MAJOR NVH EXCITATION SOURCE WITHIN THE VEHICLE

VERIFICATION (Test Procedure) 14.8L HDE COMPONENT STATIC STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION ACCEPTANCE CRITERIA No Structural Resonances below 105 Hz Equivalent to 3rd Order Forcing Function at 2100 RPM) VERIFICATION (Test Procedure) Measure Static Frequency Response Function (FRF) Test Set-up Impact Hammer or Shaker Force Input Single or Multiple Accelerometer Response Points Operating Condition: Static – Engine NOT running Test Output Transfer Function – Identifies Resonant Frequencies, Modal Stiffness & Damping CORRECTIVE ACTION (If Acceptance Criterion Is Violated) Shift Resonant Frequency (Increase or Reduce Stiffness) Reduce amplitude by increasing structural damping Repeat FRF Test to Verify Effect on Vibration Behavior VALIDATION (Test Procedure) Conduct Component Fatigue Life Evaluation Shaker Input Survive 10 Million Cycles (Infinite Life) @ Resonant Frequency

VERIFICATION (Test Procedures) 14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION PAGE 1 OF 2 ACCEPTANCE CRITERIA Vibration amplitude less than 5 mils below 105 Hz (3rd Order @ 2100 Hz) No evidence of High Amplitude Resonances Within Engine Operating Conditions (*) No evidence of High Amplitude Order Related Vibration Within Engine Operating Conditions (*) (*) Vibration measured in (a) peak acceleration (< 500 HZ) & (b) peak-to-peak displacement (< 250 Hz) VERIFICATION (Test Procedures) Generate 2D Peak Hold Spectra Test Set-up Tri-Axial Accelerometer Response Positions Same as Static FRF Operating Conditions: Full Load Speed Sweep (1050 RPM to 1850 RPM) Over 90 Seconds No Load Speed Sweep (Idle to 2100 RPM) Over 90 Seconds Test Output: 2D Peak Hold Spectrum (Peak Acceleration- 0 to 500 Hz) 2D Peak Hold Spectrum (Peak-to-Peak Displacement - 0 to 250 Hz) Generate 3D Campbell Plots Same as #1 a) Same as #1 b) 3D Campbell Plot (Peak Acceleration- 0 to 500 Hz) 3D Campbell Plot (Peak-to-Peak Displacement - 0 to 250 Hz)

CORRECTIVE ACTION (If Acceptance Criteria Are Violated) 14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION CORRECTIVE ACTION (If Acceptance Criteria Are Violated) Shift Resonant Frequency (Increase or Reduce Stiffness) Reduce amplitude by increasing structural damping Repeat FRF Test to Verify Effect on Vibration Behavior VALIDATION (Test Procedure) Conduct Component Fatigue Life Evaluation Shaker Input Survive 10 Million Cycles (Infinite Life) @ Resonant Frequency PAGE 2 OF 2

VERIFICATION (Test Procedure) 14.8L HDE TRUCK BYSTANDER SOUND LEVEL (Page 1 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION ACCEPTANCE CRITERIA TRUCK: Legal Compliance NAFTA Pass-by: NAFTA: EPA CFR 205 {SAE J366B} = 80 dB(A) @ 15 m Stationary: NAFTA: EPA CFR 325 {SAE J1096} = 85 dB(A) @ 15 m TRUCK / ENGINE: Trucks NAFTA Design Goal Pass-by: Truck = 78.3 dB(A) - Maximum Level to Insure Minimal Production Audit Engine = 75.3 dB(A) - < 51% Contribution to Total Truck Pass-by Level VERIFICATION (Test Procedure) Measure Truck Pass-by Sound Level Test Set-up Certified Pass-by Facility {Chelsea} Radar, Vehicle Telemetry & Spectral Sound Data Acquisition Microphone 15 m to the Left & Right of Vehicle Path Operating Condition: J366B Mid-Gear Full Throttle Acceleration Test Output Overall SPL & Spectra for Left & Right Sides of Vehicle Versus Track Position Truck Position, Truck Speed & Engine Speed Versus Track Position Measure Truck Stationary Sound Level Certified Stationary Facility {Chelsea} Engine Speed & Sound Data Acquisition Microphones 15 m from Right, Left, Front & Rear of Stationary Vehicle Operating Condition: No Load Acceleration / Deceleration (Idle – Max Gov Speed – Idle) Test Output: Peak Hold SPL & Spectra for Left, Right, Front & Rear of Vehicle

CORRECTIVE ACTION (If Acceptance Criteria Are Violated) 14.8L HDE TRUCK BYSTANDER SOUND LEVEL (Page 2 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION CORRECTIVE ACTION (If Acceptance Criteria Are Violated) Conduct Pass-by or Stationary Vehicle Sound Source Evaluation Acoustical Mask Entire Power Train Expose Each Power Train Element Separately to Identify Source Contribution If Engine Is A Significant Noise Source (DDC NVH Group Responsibility) Apply NVH Counter Measures to One or More Engine or After Treatment Components Engine Dyno Stand Tests May be Necessary to Identify & Treat Correct Engine Sources If Non-Engine Sources Are Significant Sources (Portland NVH Group Responsibility) Intake, Exhaust, Transmission, Driveline, Drive Axle &/or Tire Acoustical Counter Measures are Necessary VALIDATION (Test Procedure) Repeat SAE J366B Pass-by Test with Power Train Noise Counter Measures Repeat SAE J1096 Stationary Test with Power Train Noise Counter Measures

VERIFICATION (Test Procedure) 14.8L HDE ENGINE MOUNT VIBRATION LEVEL ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION ACCEPTANCE CRITERIA Transmissibility << 1.0 At Frequencies Greater than 1.4 X Fn Mount Transmissibility = Vibration Frame Side of Mount / Vibration Engine Side of Mount VERIFICATION (Test Procedure) Measure Front & Rear Mount Transmissibility Test Set-up Tri-Axial Accelerometers on Frame & Engine Side of Each Mount Truck on Chassis Dynamometer Operating Conditions: Full Load Speed Sweep (Idle to 1850 RPM) No Load Speed Sweep (Idle to 2100 RPM) Steady State: Idle, 1200 RPM, 1800 RPM, 2100 RPM Test Output Peak Acceleration & Peak-to-Peak Displacement (X, Y & Z Directions) Transmissibility (X, Y & Z Directions) CORRECTIVE ACTION (If Acceptance Criterion Is Violated) Alter Mount Stiffness Alter Mount Design (Shear versus Compression Mount) VALIDATION (Test Procedure) Repeat Front & Rear Mount Transmissibility Measurements with Revised Mounts

VERIFICATION (Test Procedure) 14.8L HDE TRUCK CABIN VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION ACCEPTANCE CRITERIA Meet > 8 Hour Vibration Exposure Limit for Steering Wheel Vibration (Per ISO 5349) Meet > 8 Hour Vibration Exposure Limit for Seat Vibration (Per ISO 2631) VERIFICATION (Test Procedure) Test Set-up Tri-Axial Accelerometers on Steering Wheel Rim & Seat Base Operating Conditions Full Load & No Load Engine Speed Sweeps Steady State Engine Operation – Idle, 1200 RPM, 1800 RPM, 2100 RPM Test Output RMS Acceleration Plotted Against ISO 5349 or ISO 2631 Exposure Limit Guidelines CORRECTIVE ACTION (If Acceptance Criteria Is Violated) Alter (& Correct if Necessary) Engine or Body Mounts Increase Steering Column Structural Damping Evaluate (& Correct if Necessary) Excessive Engine Vibration VALIDATION (Test Procedure) Repeat Steering Wheel & Seat Vibration Measurements After Corrective Action

14.8L HDE TRUCK CABIN SOUND LEVEL ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION ACCEPTANCE CRITERIA 68 dB(A) at Driver’s Ear at 60 MPH WOT (Freightliner Metric) As Good or Better than Volvo Cabin Sound Level (Industry Benchmark) Sound Pressure Level (All Occupant Positions) Zwicker Sound Quality Metrics (All Occupant Positions) VERIFICATION (Test Procedure) Test Set-up Microphone 6 inches From Driver or Occupant’s Right Ear Operating Conditions Over-the-Road & Stationary Full Throttle Acceleration (1000 RPM – 2100 RPM) Constant Speed Stationary (Idle,1200RPM, 1800 RPM & 2100 RPM) 60 MPH Constant Speed Operation with Loaded Trailer Test Output A-Weighted Overall Levels and One-Third Octave Spectra Zwicker Loudness (Sharpness, Fluctuation Strength, Roughness, Modulation) CORRECTIVE ACTION (If Acceptance Criteria Are Violated) Improve Cabin Barrier & Absorption Material Reduce Power Train Sound Level (Engine, Transmission, Exhaust, Tires Etc) VALIDATION (Test Procedure) Repeat Cabin Sound Level Analysis After Corrective Action

25 OCT 2006 NVH METHODOLOGY PRESENTATION APPENDIX CV-DS ISSUES & DELIVERABLES

DDC CV-DS NVH DELIVERABLES (page 1 of 2) 9 AUGUST 2006 NVH METHODOLOGY PRESENTATION

DDC CV-DS NVH DELIVERABLES (page 2 of 2) 9 AUGUST 2006 NVH METHODOLOGY PRESENTATION