HDE 14.8 CV-DS NVH PLAN

1. HDE 14.8 CV-DS NVH PLAN EV ARNOLD, ERIC LEITZINGER, BRYAN UNDERWOODSUSTAINING ENG‘G & NVH25 OCTOBER 2006

2. 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

3. 14.8L HDE COMPONENT STATIC STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION25 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

4. 14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATIONACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION25 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 • Test Set-up • Same as #1 a) • Operating Conditions: • Same as #1 b) • Test Output: • 3D Campbell Plot (Peak Acceleration- 0 to 500 Hz) • 3D Campbell Plot (Peak-to-Peak Displacement - 0 to 250 Hz)

5. 14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATIONACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION25 OCT 2006 NVH METHODOLOGY PRESENTATION PAGE 2 OF 2 • 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

6. 14.8L HDE TRUCK BYSTANDER SOUND LEVEL (Page 1 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION25 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 • Test Set-up • 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

7. 14.8L HDE TRUCK BYSTANDER SOUND LEVEL (Page 2 of 2)ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION25 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

8. 14.8L HDE ENGINE MOUNT VIBRATION LEVELACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION25 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

9. 14.8L HDE TRUCK CABIN VIBRATIONACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION25 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

10. 14.8L HDE TRUCK CABIN SOUND LEVELACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION25 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

11. 25 OCT 2006 NVH METHODOLOGY PRESENTATION APPENDIX CV-DS ISSUES & DELIVERABLES

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

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