NHTSA ID Number: 10199602
Manufacturer Communication Number: 0212-16
TSB/Document Date: 2021-08-02
Summary
Installation of the 1-box to the vehicle.
02 12-16
1
02 12-16
SUBJECT
DATE
EPA10 - 1-BOX™ from the vehicle
February 2016
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Change
DDC-SVC-MAN-0083
DD Platform - EPA10
Installation of the 1-BOX™ to the
Vehicle
Added Notice and graphic regarding the step
mounting nut change.
All information subject to change without notice.
02 12-16
Copyright © 2016 DETROIT DIESEL CORPORATION
3
2 Installation of the 1-BOX™ to the Vehicle
2
Installation of the 1-BOX™ to the Vehicle
WARNING: BODILY INJURY
To avoid injury from a falling component, ensure an appropriately rated lifting device is used.
Moving the component without an appropriately rated lifting device could result in the component
falling, which could cause serious personal injury and component damage. Never stand beneath a
suspended load.
Installation as follows:
If the 1-BOX is being replaced with a new 1-BOX, perform the following. If not, Go to step 3.
1. Transfer rear mounting bracket over to the new Aftertreatment Device (ATD) and hand-tighten the bolts.
2. Transfer all parts over to new ATD.
• Sensor box: Refer to section "Installation of the EPA10 1-BOX™ Sensor Box"
• Diesel Exhaust Fluid metering unit: Refer to section "Installation of the Diesel Exhaust Fluid Metering Unit"
• Diesel Exhaust Fluid nozzle supply hose: Refer to section "Installation of the Diesel Exhaust Fluid Nozzle"
• Diesel Particulate Filter: Refer to section "Installation of the EPA10 Diesel Particulate Filter"
• 1-BOX heat shields
3. Using ATD lifting device W060589003100, carefully raise the 1-BOX to the vehicle's frame and align the 1-BOX
mounting brackets to the holes in the vehicle's frame.
4. Install the four bolts and nuts (1) on the front mounting bracket attaching the 1-BOX to the front mounting bracket.
Hand-tighten bolts.
5. Install the four bolts and nuts (1) attaching the 1-BOX to the top mounting brackets and hand tighten.
4
All information subject to change without notice.
Copyright © 2016 DETROIT DIESEL CORPORATION 02 12-16
02 12-16
6. Torque the front mounting bracket bolts and nuts to 134-135 N·m (99-100 lb·ft).
7. Torque the top mounting bracket bolts to the 1-BOX to 64-88 N·m (47-65 lb·ft).
8. Install the three bolts (1) and nuts attaching the rear mounting bracket to the vehicle's frame. Torque to 134-169 N·m
(99-125 lb·ft).
9. Install the two 14-pin electrical harness connectors (1) to the sensor box.
All information subject to change without notice.
02 12-16
Copyright © 2016 DETROIT DIESEL CORPORATION
5
2 Installation of the 1-BOX™ to the Vehicle
10. Connect the compressed air line connection (1) to the DEF metering unit by pushing it into the "quick-connect"
connection.
11. Connect the DEF feed line (2) to the DEF metering unit and to the mounting clip (3) on the 1-BOX.
Table 1.
NOTE: Electrical harness connectors are keyed to prevent incorrect installation. Electrical harness connectors will close and latch
without the use of force if installed in their proper positions.
12. Ensure that the DEF feed line is routed correctly under the frame rail of the vehicle and is connected to the tab on the 1BOX.
6
All information subject to change without notice.
Copyright © 2016 DETROIT DIESEL CORPORATION 02 12-16
02 12-16
13. Connect the six electrical harness connectors (1 - 6) to the DEF metering unit.
14. Install the DEF metering unit cover (1) and tighten the screws (2).
All information subject to change without notice.
02 12-16
Copyright © 2016 DETROIT DIESEL CORPORATION
7
2 Installation of the 1-BOX™ to the Vehicle
NOTE: The exhaust system outlet pipe clamps are directional; verify correct installation.
15. Install a new gasket (1) onto the 1-BOX exhaust outlet and then connect the exhaust system outlet pipe by installing the
clamp. Torque to 9-10 N·m (79-88 lb·in.).
16. Install a new gasket (1) onto the 1-BOX exhaust inlet and then connect the exhaust system inlet pipe by installing the
clamp. Torque to 9-10 N·m (79-88 lb·in.).
8
All information subject to change without notice.
Copyright © 2016 DETROIT DIESEL CORPORATION 02 12-16
02 12-16
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
17. Connect the batteries.
18. Check for any leaks.
All information subject to change without notice.
02 12-16
Copyright © 2016 DETROIT DIESEL CORPORATION
9
2 Installation of the 1-BOX™ to the Vehicle
Table 2.
NOTICE: The 1-BOX welded step mounting nuts have changed from standard to metric. If a new service replacement 1BOX is being installed and the serial number is 12400004909082 or greater, all eight step mounting bolts (1) will need to
be replaced with Class 10.9 (M12 X 1.5 X 30) bolts, part number 23-14065-030. The washers have NOT changed.
19. If removed, install the passenger side fairing. Refer to OEM procedures.
10
All information subject to change without notice.
Copyright © 2016 DETROIT DIESEL CORPORATION 02 12-16
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TSB/Document ID: 0212-16
Replacement Service Bulletin Number:
MFR Communication Date: 2016-02-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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