MACK CHU Operator's Manual
Mack
®
CHU Series
®
Mack
Pinnacle
TM
Series
(CHU Series)
TM
Mack® Pinnacle
Series
(CHU Series)
21394649
© Mack Trucks, Inc. 2010
Printed in U.S.A.
21394649
21394649
April 2010
Foreword
Thismanualcontainsinformationconcerningtheandfunctionofthe
MackLinkSystem.Theinformationinthismanualappliestovehicles
builtApril2010andlater.Pleasekeepthismanualinthevehicleat
alltimes.
Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)and
MackTrucksInc.shouldbeinformedimmediatelyifyoubelievethat
thevehiclehasadefectthatcouldcauseacrash,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)
327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation,
Washington,DC20590,byTTYat1(800)424-9153,orvisittheir
websiteatwww.nhtsa.dot.gov.
MackTrucks,Inc.
Greensboro,NCUSA
Ordernumber:PV776-21394649
©2010MackTrucks,Inc.,Greensboro,NCUSA
Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionofMackTrucks,Inc.
Contents
INTRODUCTION............................................................................................................1
TOTHEOWNER..........................................................................................................1
InAppreciation..........................................................................................................1
AboutThisHandbook................................................................................................2
THEVEHICLE..............................................................................................................3
BasicConguration...................................................................................................3
VehicleManagementandControlSystem(V-MAC®).............................................3
COMPONENTIDENTIFICA TION..............................................................................4
VINLocations............................................................................................................4
EngineIdentication..................................................................................................5
EngineInformationPlate...........................................................................................6
CleanIdleEngines.....................................................................................................7
TransmissionIdentication........................................................................................8
WARRANTYINFORMA TION..................................................................................11
AirBrakeSystem.....................................................................................................11
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................12
EmissionsControlSystemW arranty.......................................................................13
ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............15
FEDERALEMISSIONREQUIREMENTS............................................................16
EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................16
EmissionsControlSystemW arranty.......................................................................18
SERVICELITERA TURE............................................................................................22
MACKClass8–ComponentsServiceManual.......................................................22
Class8–CustomCollatedServiceManualonCD.................................................22
CUSTOMERSERVICE..............................................................................................23
Call1-800-866-1177forMACKOne-Call™..........................................................23
QuestionsandComplaints.......................................................................................23
Addresses.................................................................................................................24
AdditionalAssistance..............................................................................................25
REPORTINGSAFETYDEFECTS.............................................................................26
UnitedStates............................................................................................................26
Canada......................................................................................................................26
Mexico.....................................................................................................................26
EVENTDA T ARECORDINGDEVICES...................................................................27
SAFETYINFORMATION...........................................................................................28
SAFETYSTA TEMENT..............................................................................................28
CERTIFICA TIONLABELS........................................................................................30
SafetyCerticationLabel........................................................................................30
ADVISORYLABELS.................................................................................................32
AdvisoryLabelLocations(OnV ehicle)..................................................................32
TRUCK-TRACTORCONSPICUITY.........................................................................43
CABENTRY/EXIT.....................................................................................................44
Three-LimbContact.................................................................................................44
DriverSide...............................................................................................................46
PassengerSide.........................................................................................................48
DeckPlateAccess....................................................................................................50
SAFETYTIPSFORCOLDWEA THER...................................................................52
DriverVisibility.......................................................................................................52
AuxiliaryCabHeater...............................................................................................53
CabDoorSealsandKeyLocks...............................................................................54
OutsideMirrorHeater..............................................................................................54
AirHornSnowShield..............................................................................................55
EmergencyReectorKit..........................................................................................55
FireExtinguisher(Optional)....................................................................................55
INSTRUMENTSANDCONTROLS...........................................................................56
CABINTERIOR..........................................................................................................56
INSTRUMENTPANEL..............................................................................................57
Tell-T ales..................................................................................................................57
PanelArrangement...................................................................................................58
INSTRUMENTPANELGAUGELA YOUT..............................................................59
PanelA.....................................................................................................................61
PanelB.....................................................................................................................62
PanelC.....................................................................................................................64
PanelD.....................................................................................................................65
FunctionofOptionalSwitches.................................................................................78
CABCLIMA TECONTROL.......................................................................................85
SLEEPERCLIMA TECONTROL..............................................................................87
LIGHTCONTROLP ANEL........................................................................................88
LOWERCONSOLEP ANEL......................................................................................89
STEERINGCOLUMN................................................................................................90
CombinationStarterandElectricalSwitch..............................................................90
SteeringWheelAdjustment.....................................................................................90
TurnSignalLever....................................................................................................91
StalkSwitch(IfEquipped,Co-Pilot®Only)...........................................................92
FLOORPEDALS........................................................................................................93
MISCELLANEOUSCONTROLS..............................................................................94
DomeLight..............................................................................................................94
InteriorCabLights(SleeperCab)............................................................................95
AirHorn...................................................................................................................95
FreshAirV ent..........................................................................................................96
CabAirFilter...........................................................................................................97
Microphone..............................................................................................................98
AccessoryPowerOutlets.........................................................................................99
.......................................................................................................................................102
PRE-TRIPINSPECTIONANDDAIL YMAINTENANCE.....................................102
Pre-TripInspectionQuickList..............................................................................103
NewV ehicleBreak-In............................................................................................114
WINDSHIELDW ASHERRESER VOIR..................................................................117
HOOD.......................................................................................................................118
OpeningtheHood..................................................................................................118
ClosingtheHood...................................................................................................120
LockingtheHood..................................................................................................121
HOSETENDERS......................................................................................................122
DOORS......................................................................................................................123
StandardDoorPanel..............................................................................................123
PowerDoorPanel(Optional).................................................................................124
OpeningtheCabDoor...........................................................................................125
LockingtheCabDoor............................................................................................125
PowerWindowRegulators....................................................................................125
REMOTEKEYLESSENTRY—(OPTIONAL)......................................................126
TransmitterOperations..........................................................................................127
BatteryReplacement..............................................................................................128
SEATBEL TS.............................................................................................................131
SeatBeltOperation................................................................................................131
FasteningSeatBelt................................................................................................131
AdjustableD-RingShoulderBelts(ifequipped)...................................................133
Komfort®LatchSystem........................................................................................134
SLEEPERBUNKRESTRAINT...............................................................................136
UpperBunk(Optional)..........................................................................................136
BunkRestraint......................................................................................................137
BunkRestraintMaintenance..................................................................................137
SEATADJUSTMENTANDRECLINE(IFEQUIPPED)........................................138
HEATEDSEA T(OPTIONAL)..................................................................................138
SWIVELSEA T(OPTIONAL)..................................................................................138
MACKENGINEINFORMA TION...........................................................................141
PrecautionsandWarnings......................................................................................141
EngineModelDesignations...................................................................................142
CRUISECONTROL................................................................................................143
SpeedControlSwitches.........................................................................................143
SettingCruiseControl...........................................................................................144
DisengagingCruiseControl...................................................................................144
MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................145
EngineBrakeSwitch..............................................................................................146
HowtheEngineBrakeisActivated.......................................................................147
CruiseControlwiththeMACKPowerLeash™EngineBrake.............................148
ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........149
OverFlatTerrain....................................................................................................149
DescendingaGrade...............................................................................................150
OnSlipperyRoadSurfaces....................................................................................152
BRAKE.....................................................................................................................154
AirBrakeSystem...................................................................................................154
AutomaticSlackAdjusters....................................................................................155
ParkingBrakeSystem............................................................................................156
ParkingBrake........................................................................................................156
Parking...................................................................................................................156
Anti-LockBrakeSystem(ABS)............................................................................157
AutomaticTractionControl(A TC)(IfEquipped).................................................162
GOODDRIVINGHABITS.......................................................................................163
WeightRatings.......................................................................................................163
Instruments.............................................................................................................163
ShuttingDowntheEngine.....................................................................................163
GeneralObservation..............................................................................................163
STARTINGTHEVEHICLE.....................................................................................164
GeneralInformation...............................................................................................164
PushButtonStarters...............................................................................................164
AirStarters.............................................................................................................165
EngineWarm-Up...................................................................................................168
EngineIdling..........................................................................................................168
ShuttingDowntheEngine.....................................................................................169
COLDWEA THEROPERA TION.............................................................................171
ColdWeatherStartingTips....................................................................................171
EngineBlockHeaters............................................................................................172
Winterfronts...........................................................................................................173
COUPLINGATRAILER..........................................................................................176
UNCOUPLINGATRAILER....................................................................................178
MOVINGTHEVEHICLE—GENERALINFORMA TION...................................180
Braking...................................................................................................................180
Shifting...................................................................................................................180
EngineTemperature...............................................................................................181
Clutch(IfEquipped)..............................................................................................182
POWERTAKE-OFF(PTO).....................................................................................186
PTOPrecautions....................................................................................................186
PTOClassication.................................................................................................187
Side-MountedPTOLocations...............................................................................187
PTOOperatingProcedures....................................................................................187
TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................188
ShiftingInstructionsforAllisonAutomaticTransmissions..................................188
MACKT306GShiftingInstructions.....................................................................189
MACKTM308ShiftingInstructions.....................................................................190
MACKTM308MShiftingInstructions.................................................................192
MACKTM309ShiftingInstructions.....................................................................194
MACKTM309MShiftingInstructions.................................................................195
MACKT309,T309LandT309LRShiftingInstructions......................................198
MACKT310ShiftingInstructions........................................................................202
MACKT310M,T310MEandT310MLRShiftingInstructions...........................205
MACKT313-T313L-T313LRShiftingInstructions.............................................209
MACKT31321,T313L21andT313LR21ShiftingInstructions..........................213
MACKT318,T318LandT318LRShiftingInstructions......................................217
MACKT31821,T318L21andT318LR21ShiftingInstructions..........................224
PrecautionsWhenDescendingGradesIfVehicleisEquippedwithEaton
AutoShiftGenerationIandII................................................................................230
AXLES.......................................................................................................................231
RearAxlesOtherThanMACK.............................................................................231
MACKRearAxles.................................................................................................231
EngagingthePowerDividerLockout....................................................................233
Mack,EPA2010EmissionsSolution...........................................................................234
DIESELPARTICULA TEFIL TERS(IFEQUIPPED)..............................................234
ExtendedIdlingandAftertreatmentSystemConditioning...................................237
ExhaustAftertreatmentSystem.................................................................................238
SafetyInformation.................................................................................................239
ExhaustAftertreatmentSystemComponentsand................................................240
SelectiveCatalyticReduction(SCR)....................................................................240
DieselExhaustFluid(DEF)...................................................................................243
AftertreatmentDieselParticulateFilter(DPF)......................................................246
AftertreatmentControlModule(ACM).................................................................247
ExhaustAftertreatmentSystem............................................................................248
DriverWarningsandOnBoardDiagnostics(OBD).............................................254
OnBoardDiagnostics(OBD)................................................................................254
InstrumentCluster..................................................................................................255
MalfunctionIndicatorLamp(MIL).......................................................................256
AftertreatmentDEFTankLevel-DriverWarning&Inducement........................257
AftertreatmentDEFQuality-DriverWarning&Inducement..............................258
MisllingDieselorAftertreatmentDEFTanks.....................................................259
SCRTampering-DriverW arning&Inducement.................................................260
WarrantyandMaintenance....................................................................................261
ExhaustAftertreatmentSystemMaintenance........................................................261
EngineMaintenanceIntervals................................................................................261
MAINTENANCEANDLUBRICATION..................................................................262
MAINTENANCEINTRODUCTION.......................................................................262
TURBOCHARGER...................................................................................................263
CLEANINGYOURVEHICLE.................................................................................263
ExteriorWashing...................................................................................................264
CabandHood........................................................................................................266
Chassis...................................................................................................................266
CabInterior............................................................................................................267
Waxing...................................................................................................................267
Polishing................................................................................................................267
WinterW arnings....................................................................................................267
TOWING...................................................................................................................268
TowingwithMACKAir(ALorMAXAIR®40)Suspension(IfEquipped).......270
ENGINEOILLEVELCHECK.................................................................................271
OilChangeIntervals..............................................................................................272
EngineMaintenanceIntervals................................................................................273
PowerSteeringReservoir......................................................................................274
FUELTANK..............................................................................................................275
FuelTankCap........................................................................................................275
FUELING..................................................................................................................275
B5ApprovalForMackUS10CertiedProducts..................................................277
COOLINGSYSTEM.................................................................................................278
CoolantLevelCheck..............................................................................................279
DrainingtheCoolingSystem.................................................................................279
RellingtheCoolingSystem.................................................................................279
ProtectingtheCoolingSystem..............................................................................280
CoolingSystemMaintenance................................................................................282
AccessoryDriveBeltRouting...............................................................................282
HEADLIGHTS..........................................................................................................283
BulbReplacement..................................................................................................283
WHEELS...................................................................................................................286
WheelInspection...................................................................................................286
Tires.......................................................................................................................287
BATTERY..................................................................................................................289
Jump-StartingEngine.............................................................................................290
ELECTRICAL...........................................................................................................292
CircuitBreakerandRelayPanels..........................................................................292
ElectricalGrease....................................................................................................295
CircuitProtectionCharts........................................................................................295
ElectricalAccessoryConnectionPoints................................................................298
METRICCONVERSIONS.........................................................................................300
METRICCONVERSIONS.......................................................................................300
SafetyInformation
IMPORTANT:Beforedrivingthis
vehicle,becertainthatyouhaveread
andthatyoufullyunderstandeachand
everystepofthedrivingandhandling
informationinthismanual.Becertain
thatyoufullyunderstandandfollowall
safetywarnings.
ITISIMPOR T ANTTHATTHE
FOLLOWINGINFORMA TIONBE
READ,UNDERSTOODANDALW A YS
FOLLOWED.
Thefollowingtypesofadvisoriesareused
throughoutthismanual:
DANGER
Dangerindicatesanunsafepracticethat
couldresultinseriouspersonalinjury
ordeath.Adangeradvisorybanneris
inwhitetypeonablackbackground
withablackborder.
WARNING
Warningindicatesanunsafepractice
thatcouldresultinpersonalinjury.A
warningadvisorybannerisinblack
typeonagraybackgroundwithablack
border.
CAUTION
Cautionindicatesanunsafepracticethat
couldresultindamagetotheproduct.
Acautionadvisoryisinblacktypeona
whitebackgroundwithablackborder.
Note:Noteindicatesaprocedure,practice,
orconditionthatmustbefollowedinorder
forthevehicleorcomponenttofunction
inthemannerintended.
CALIFORNIAPROPOSITION65W ARNING
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCalifornia
tocausecancer,birthdefectsandotherreproductiveharm.
CALIFORNIAPROPOSITION65W ARNING
Batteryposts,terminalsandotherrelatedaccessoriescontainleadandlead
compounds,chemicalknowntotheStateofCaliforniatocausecancerandother
reproductiveharm.
BatteriesalsocontainotherchemicalsknowntotheStateofCaliforniatocausecancer.
Washhandsafterhandling.
INTRODUCTION1
TOTHEOWNER
InAppreciation
ThankyouforbuyingaMACK®vehicle.Withpropercareandmaintenance,
yournewMack®Pinnacle™modelwillhelpyougainacompetitiveedgewith
itsfuel-efcientdrivetraincombinations,lowmaintenance,extendedservice
intervalsand,eventually,goodresalevalue.
TheMack®Pinnacle™modelisavailableforawiderangeofapplications.
Becauseofthisversatility,drivetrainsandcomponentsvaryandoperating
instructionsmaydifferfromonemodeltoanother.Whileeveryefforthas
beenmadetocoverallcurrentarrangements,donothesitatetoconsultyour
MACKdistributorifaquestionarises.Honest,personalserviceisstandard
witheveryMACKsale.
CAUTION
MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin
thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.
We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack®
Pinnacle™model,andthatyouseemanyyearsoftrouble-freedriving.
Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations
applicableatthetimeofmanufacture.
2INTRODUCTION
AboutThisHandbook
ThishandbookisreferredtoastheMack®Pinnacle™SeriesOperator’s
Handbook.ItcoversallMack®Pinnacle™CHUmodels.Keepthishandbook
withthevehicleatalltimestoensurethateachownerand/oroperatorwillhave
accesstoallpertinentinformationrelatingtotheandhandlingofthisvehicle.
Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation
concerningthedailyuseofthisvehicle.Pleasereaditthoroughly;pay
particularattentiontoadvisorylabelsthathavebeenincludedtodrawattention
toimportantissuesofoperatorsafetyandoverallperformance.
Informationandillustrationsinthishandbookarebasedonthelatest
productionusageatthetimeofprintingandaresubjecttochangewithout
priornotice.
Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual.
Forfurtherinformation,refertotheMaintenanceandLubricationManual.Other
importantinformationcanbefoundintheEmissionControlSystemsforMACK
DieselEngineManual.
INTRODUCTION3
THEVEHICLE
BasicConguration
TheMack®Pinnacle™modelfeaturesaconventionallystyled,aerodynamiccab.
VehicleManagementandControlSystem
(V-MAC®)
TheV ehicleManagementandControlSystem(V-MAC)isanelectronic
controlsystemthatmanagesengineandvehiclefunctions.Inaddition,the
DataMax™portionofV-MACmonitorsandstoresavarietyofinformation(i.e.,
maintenanceschedules,overspeedlogs,faulttables,tripsummaries).
ForacompletedescriptionoftheV-MACIVsystem,refertotheapplicable
V-MAC®Operator’sGuide,whichissuppliedwiththevehicle.
Additionalinformationconcerningservice,diagnostics,programmingand
vendorequipmentinterfaceapplicationisavailablefromtheMackTrucks,Inc.
ServicePublicationsDepartment.ContactyourlocalMACKdealerfordetails.
WARNING
NevercutintotheV-MACsystemwireharnesstopoweradditionalequipment.If
suchequipmentistobeinstalled,contactyourMACKdealerforassistance.
4INTRODUCTION
COMPONENTIDENTIFICATION
Locatethefollowingserialnumbersandwritethemintheboxesprovided
nexttoeachillustration.
VINLocations
TheVehicleIdenticationNumber(VIN)isdisplayedintwolocations(aframe
railstampingandalabel).The17-digitVINmustbeidenticalinbothlocations.
TheVINframestampingislocatedonthebottomrightframerailangeand
thetopleftrailange.NotethattheVINlocationmayvaryifre-stampingof
theframebecomesnecessary.
TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.
C0028939
C0028940
INTRODUCTION5
C0028941
EngineIdentication
OntheMACKMPengines,theengineserialnumberisstampedontheleft
sideoftheengineblock,belowtheinletmanifold.
C0028943
6INTRODUCTION
EngineInformationPlate
IncompliancewithFederalemission
requirements,anengineinformationlabel
isafxedtoallMackdieselengines.This
label,whichislocatedonthecylinderhead
coveratthefrontoftheengine,givesbasic
engineidenticationinformation(engine
EngineIdenticationLabel—49StateEP AApprovedEnginewithoutCalifonia“CleanIdle”
model,serialnumber,etc.),advertised
horespoweratratespeed,inletandexhaust
valvelashsetting.TheEnginefamily
“A VPTH12.8S01”canbeusedtoidentify
theemissionstandardunderwhichthe
enginewascertied.
W2040455
W2040456
EngineIdenticationLabel—50StateEPAApprovedEnginewithCalifonia“CleanIdle”
INTRODUCTION7
CAUTION
Tomaintaincompliancewithemission
regulations,enginesettingsshouldnot
bechangedfromthosespeciedonthe
engineinformationlabel.
Note:BoththeU.S.EPAandCalifornia
AirResourcesBoardrequiresthateach
enginebeidentiedwiththeproperengine
labelasshownabove.Shouldthisengine
labelbedefaced,destroyed,orremoved
fromthevalvecover,itmustbereplaced
immediately.Toorderareplacement
label,pleasecontactSpecications
orPartsInterpretationsdepartmentat
1–800–888–9878,Option2,whowill
assistyouinobtainingthecorrectlabelfor
yourengine.
CleanIdleEngines
TheCaliforniaAirResourcesBoard(ARB)requiresthat2008andlatermodel
yearvehiclesbeequippedwithengineshavingtamper-resistantsoftware
whichlimitsthetimeatwhichtheenginecanidleatspeedsabovelowidle
(550–700rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idle
timewillbelimitedtoveminutes,afterwhichtheenginewillrevertbacktolow
idle.VehiclesequippedwithaCleanIdleengineareidentiedbyalabelwhich
isafxedtotheleftfrontcornerofthehoodonconventionalmodels(CHU).
CleanIdleEngineLabel
W2056289
8INTRODUCTION
TransmissionIdentication
TheMACKT300Seriestransmissionserialnumberislocatedontherear
leftsideofthemaincase.
C0028947
TheAllisonRDSandHStransmissionidenticationplateislocatedonthe
rearrightsideofthemaincase,nearthelowerend.
C0028948
AllEaton®Fuller®transmissionidenticationplatesarelocatedonthe
frontleftsideofthemaincase.
C0028949
TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside
ofthehousing.
INTRODUCTION9
C0028950
TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe
axlehousingtowardthecarrier.
C0028951
TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft
sideoftheforwardcarrier,andthetopoftherearcarrier.
C0028952
TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof
therearaxlehousing,nexttothecarrier .
10INTRODUCTION
C0028953
TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof
theforwardcarrier,andthetopoftherearcarrier.
C0028954
INTRODUCTION11
WARRANTYINFORMATION
ThischassisisequippedwithaUS2010emissioncompliantenginewithan
engineexhaustaftertreatmentsystem(DieselParticulateFilter)andselective
catalyticreduction(SCR)system.UseofUltraLowSulfurDiesel(ULSD)fuel
andEO-OPremiumPlus(orVDS-4)specicationhighperformancediesel
engineoilisrequiredinthisvehicle.
Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand
aftertreatmentsystemwarranty.
AirBrakeSystem
TheMACKStandardVehicleWarrantyappliestotheairbrakesystem,as
setforthintheWarranty,butonlyiftheairbrakesystemhasnotbeen
subjectedtounauthorizedadditions,deletionsormodications.Ifanysuch
unauthorizedadditions,deletionsormodicationsareperformed,Mack
Trucks,Inc.disclaimsanyandallliabilityforanylossordamagearisingoutof
amalfunctionoftheairbrakesystem.
Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable
federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.
Tractorairsystemsaredesignedforasatractoronly,andtruckairsystems
aredesignedtobeoperatedasatruckonly.Ifatractorisgoingtobe
convertedforasatruck,theairbrakesystemmustbereconguredtothat
ofatruck.Conversely,ifatruckisgoingtobeconvertedforasatractor,the
airbrakesystemmustbereconguredtothatofatractor.Consultyourlocal
MACKdistributorforadditionalinformation.
Ifanyunauthorizedadditions,deletionsormodicationsaremadetoany
portionoftheairbrakesystemwhichisrequiredbyFederalMotorVehicle
SafetyStandards,MackTrucks,Inc.makesnorepresentationastoconformity
withtheStandards.
Forcompletewarrantyinformation,refertothePedigreedProtectionPlan
providedwitheachvehicle.
12INTRODUCTION
ENGINEGASEOUSEMISSIONCONTROL
SYSTEMS
WARRANTYMAINTENANCE
Note:Foremissioncontrolsystems
informationonenginesotherthanMACK,
refertotheenginevendor’spublication
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS
WARRANTY
MackTrucks,Inc.warrantstheEmission
ControlSystemsoneachnewMack
dieselengineinanewMackTruckto
complywithallUnitedStatesFederal
andCanadianemissionsregulations
applicableatthetimeofmanufactureof
theengine,andtobefreefromdefects
inmaterialandworkmanshipunder
normaluseandserviceupto60months,
or160934km(100,000miles),which
everoccursrst,providedthatallMack
Trucks,Inc.maintenancerequirements
arefollowedasdescribedinthismanual.
Allwarrantyperiodsarecalculatedfrom
thedate-in-serviceofthenewvehicle.
Therepairorreplacementofdefective
partswillbemadewithoutchargefor
thecostofpartsandifrepairsaremade
atanauthorizedMackTrucks,Inc.
dealership,therewillbenochargefor
labor.MackTrucks,Inc.’sobligation
underthiswarrantyislimitedtotherepair
orreplacement,atMackTrucks,Inc.’s
option,ofanypart(s)oftheEmission
ControlSystemsofsuchengineand/or
vehiclefoundtobedefectiveupon
examinationbyMackTrucks,Inc.and
providedthatsuchpart(s)werereturnedto
MackTrucks,Inc.oritsnearestauthorized
Dealerwithinareasonableperiodoftime.
QualicationsandLimitations:
Note:NotcoveredbytheEmissions
ControlSystemsWarranty:
•Malfunctionscausedbymisuse,
improperadjustments,modication,
alteration,tampering,disconnection,
improperorinadequatemaintenance
anduseofimproperdieselfuelorDEF.
•Inconvenience,lossofuseofthe
vehicle,commerciallossofany
kindincluding,butnotlimitedto,
consequentialorincidentaldamages
•Anyvehicleinwhichtheodometer
hasbeenalteredordamagedsothat
mileagecannotbereadilydetermined.
•Damageresultingfromaccident,acts
ofnatureorothereventsbeyondthe
controlofMackTrucks,Inc.
THISW ARRANTYISEXPRESSL YINLIEUOFALLOTHERW ARRANTIES
ANDREPRESENT A TIONSORCONDITIONS,STA TUTORYOR
OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED
TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA
PARTICULARPURPOSE.
INTRODUCTION13
EmissionsControlSystemWarranty
Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.
1TurbochargerAssembly
•VGTActuator
2ChargeAirCooler
•CACPipes(Airinletto/fromCAC)
•CACHoses
3EngineControlModule(ECM)
4Injectors
5EngineandV ehicleWireharness(
repairtocircuitsrelatedtoEmissions
WarrantableComponents)
6ExhaustGasRecirculation(EGR)
Mixer
7EGRCooler
8EGRV alveandEGRValveControl
9EGRPipes-EngineExhaustManifold
toEGRCooler
10EGRPipes-EGRCoolertoInlet
Manifold
11CrankcaseBreather
12CrankcaseSeparator
13CrankcaseTubingandHosesbefore
Separator
14AftertreatmentWiringHarness
15AftertreatmentControlModule(ACM)
16AftertreatmentDieselParticulateFilter
(DPF)Assembly
A.AftertreatmentDPFAssembly
withAftertreatmentDieselOxidation
Catalyst(DOC)
•AftertreatmentDoser
•DiffuserPipe(AftertreatmentFuel
DoserMounting)
•FuellinestoAftertreatmentFuel
Doser
•AftertreatmentFuelShutoffV alve
•AftertreatmentFuelPressureSensor
•DischargeRecirculationV alve
(DRV)(HeatMode)
•DischargeRecirculationV alve
(DRV)Solenoid
•EngineTurbochargerCompressor
BypassActuator(HeatMode)
•EngineTurbochargerCompressor
BypassActuatorSolenoid
•EngineExhaustGasT emperature
(EGT)Sensor
•AftertreatmentDPFIntake
TemperatureSensor
•AftertreatmentDPFOutlet
TemperatureSensor
•AftertreatmentDPFDifferential
PressureSensor
•AftertreamentDoserAirSupply
Regulator(ifapplicable),Supply
Lines,andFittings
B.ThermalRegenerationUnit(TRU)
•AftertreatmentDPFCombustion
AirControlValve
•AftertreatmentDPFCombustion
AirValve
•AftertreatmentDPFAtomization
Module
•AftertreatmentDPFIgnitionCoil
•AftertreatmentDPFFuelControl
Valve
•AftertreatmentDPFIgnition
Electrode
•Nozzle
•EngineExhaustGasT emperature
(EGT)Sensor
•AftertreatmentDPFIntake
TemperatureSensor
14INTRODUCTION
•AftertreatmentDPFOutlet
TemperatureSensor
•AftertreatmentDPFSparkAssist
FlameTemperatureSensor
•AftertreatmentDPFDifferential
PressureSensor
17Sensors:
•CrankshaftPosition(CKP)
•CamshaftPosition(CMP)
•EngineCoolantTemperature(ECT)
•IntakeManifoldAirTemperature
•IntakeManifoldPressure(IMP)
•EGRTemperature
•AftertreatmentOutletNOx
•AftertreatmentIntakeNOx
•EGRDifferentialPressure
•AmbientAirTemperature(AA T)
18SCR
•AftertreatmentSelectiveCatalytic
Reduction(SCR)Catalyst
•AftertreatmentDieselExhaustFluid
(DEF)Pump
•AftertreatmentDEFDosing
AbsolutePressureSensor
•AftertreatmentDEFReturn
Valve
•AftertreatmentDEFDosingV alve
•AftertreatmentDEFTank
•AftertreatmentDEFTank
Heater/Sender
•AftertreatmentDEFTankHeater
•AftertreatmentDEFT ankHeater
Valve
•AftertreatmentDEFTank
TemperatureSensor
•AftertreatmentDEFLevelSensor
•AftertreatmentDEFHeatedLines
19.InstrumentCluster(Repairof
microprocessor,OBDMIL,RealTime
Clock,AftertreatmentDEFTankGauge
and,AftertreatmentDEFTankLowLevel
Indicator)
20.ExhaustGasPiping(from
TurbochargertoAftertreatmentSystem)
21.DataLinkConnector(DLC)
ENGINEGASEOUSEMISSIONSCONTROL
SYSTEMWARRANTY
INTRODUCTION15
Theemissionwarrantyforthediesel
particulatelter(DPF)andSCRSystem
coversdefectsinworkmanshiponly .
Normalmaintenance,suchascleaning
ashfromthelteratregularmaintenance
intervalsandcleaningtheaftertreatment
fuelinjectoronDieseloxidationcatalyst
(DOC)DPFsystems,isnotcoveredby
theemissionwarranty.WiththeThermal
regeneratorDPFsystem,cleaningthe
ignitionelectrodesandfuelinjection
nozzleattheregularmaintenanceintervals
isconsiderednormalmaintenanceandnot
coveredbytheemissionwarranty.
Note:Inresponsetocustomerrequests,
MackTrucks,Inc.maybuildvehicleswith
enginessuppliedbyothermanufacturers.
Inthesecases,eachenginemanufacturer
throughitsserviceorganization,is
responsibleforemissioncontrolsystems
warrantyonallpartsoftheengine
assembly,asfurnished.
16INTRODUCTION
FEDERALEMISSIONREQUIREMENTS
Thissectioncoverstherequirementofthe
UnitedStatesCleanAirActwhichstates:
“Themanufacturershallfurnishwith
eachnewmotorvehicleormotorvehicle
enginesuchwritteninstructionsforthe
maintenanceanduseofthevehicleor
enginebytheultimatepurchaserasmay
TAMPERINGWITHGASEOUSEMISSIONCONTROLSYSTEMS
PROHIBITED
TheFederalCleanAirActprohibitsthe
removalorrenderinginoperativeofany
deviceorelementofdesigninstalledonor
inamotorvehicleormotorvehicleengine
incompliancewithFederalEmission
Regulationsby:
1Anypersonpriortoitssaleanddelivery
totheultimatepurchaser,or
2Anymanufacturerordistributorafter
itssaleanddeliverytotheultimate
purchaser,or
3Anypersonengagedinthebusinessof
repairing,servicing,selling,leasing,or
bereasonableandnecessarytoassurethe
properfunctioningofemissioncontrol
devicesandsystems.”Thissectionalso
coverstherequirementsoftheemissions
regulationspromulgatedundertheMotor
VehicleSafetyActinCanada.
4Anypersonwhooperatesaeetof
Note:Forspecicsoftheprohibited
vehicle/enginemodicationsreferto
theMackTrucks,Inc.BodyBuilders
documentation.
tradingmotorvehiclesormotorvehicle
enginesfollowingitssaleanddelivery
totheultimatepurchaser,or
motorvehiclesfollowingitssaleand
deliverytotheultimatepurchaser.
EMISSIONCONTROLSYSTEMSWARRANTY—
CALIFORNIA
TheCaliforniaAirResourcesBoardand
MackTrucks,Inc.arepleasedtoexplain
theCaliforniaemissioncontrolsystem
warrantyonyournewmotorvehicle
engine.InCalifornia,newmotorvehicle
enginesmustbedesigned,builtand
equippedtomeettheState’sstringent
anti-smogstandards.MackTrucks,Inc.
mustwarranttheemissioncontrolsystem
onyourenginefortheperiodoftimelisted
belowprovidedtherehasbeennoabuse,
neglect,orimpropermaintenanceofyour
engine.
Youremissioncontrolsystemmay
includepartssuchasthefuel-injection
system,turbochargerassembly,electronic
controlmoduleandotheremission-related
assemblies.
Whereawarrantableconditionexists,
MackTrucks,Inc.willrepairyourengine
atnocosttoyouincludingdiagnosis,
parts,andlabor.
MANUFACTURER’SWARRANTY
COVERAGE:
Ifanemission-relatedpartofyourengine
isdefective,thepartwillberepairedor
replacedbyMackTrucks,Inc.Thisis
youremissioncontrolsystemDEFECTS
WARRANTY .
OWNER’SWARRANTYRESPONSIBILITIES:
INTRODUCTION17
Asthemotorvehicleengineowner,you
areresponsiblefortheperformanceof
therequiredmaintenancelistedinthis
manual.MackTrucks,Inc.recommends
thatyouretainallreceiptscovering
maintenanceofyourvehicle,butMack
Trucks,Inc.cannotdenywarrantysolely
forthelackofreceiptsorforyourfailure
toensuretheperformanceofallscheduled
maintenancelistedinothermanualswhich
weresuppliedwithyourvehicle.
Youareresponsibleforpresenting
yourmotorvehicleenginetoaMACK
dealerassoonasaproblemexists.The
warrantyrepairsshouldbecompleted
inareasonableamountoftime,notto
exceed30days.Asthemotorvehicle
engineowner,youshouldalsobeaware
thatMackTrucks,Inc.maydenyyou
warrantycoverageifyourvehicleora
parthasfailedduetoabuse,neglect,
impropermaintenance,orunapproved
modications.
Ifyouhaveanyquestionsregarding
yourwarrantyrightsandresponsibilities,
youshouldcontacttheMackTrucks,
Inc.WarrantyActivitiesP.O.Box26259,
Greensboro,NC27402,ortheCalifornia
AirResourcesBoardat9480Telstar
Avenue,ElMonte,California91731.
(Applicableonlytovehiclesand/or
enginescertiedforsaleandregistered
intheStateofCalifornia)MackTrucks,
Inc.warrantstheEmissionControl
SystemsoneachnewMACKdiesel
engineinanewMACKtrucktocomply
withallStateofCaliforniaemissions
regulationsapplicableatthetimeof
manufactureoftheengine,andtobefree
fromdefectsinmaterialandworkmanship
undernormaluseandserviceupto
60months,or100,000miles,or3,000
engineoperatinghours,whicheveroccurs
rst,providedthatallMackTrucks,
Inc.maintenancerequirementsare
followedasdescribedinthismanual.All
warrantyperiodsarecalculatedfromthe
date-in-serviceofthenewvehicle.The
repairorreplacementofdefectiveparts
willbemadewithoutchargeforthecost
ofpartsand,ifrepairsaremadeatan
authorizedMackTrucks,Inc.dealership,
therewillbenochargeforlabor.
MackTrucks,Inc.’sobligationunder
thiswarrantyislimitedtotherepair
orreplacement,atMackTrucks,Inc.’s
option,ofanypart(s)ofEmissionControl
Systemsofsuchengineand/orvehicle
foundtobedefectiveuponexaminationby
MackTrucks,Inc.andprovidedthatsuch
part(s)werereturnedtoMackTrucks,Inc.
oritsnearestauthorizedDealerwithina
reasonableperiodoftime.
QualicationsandLimitations:
NotcoveredbytheEmissionsControl
SystemsWarranty:
•Malfunctionscausedbymisuse,
improperadjustments,modication,
alteration,tampering,disconnection,
improperorinadequatemaintenance
anduseofimproperdieselfuelorDEF.
•Damageresultingfromaccident,acts
ofnatureorothereventsbeyondthe
controlofMackTrucks,Inc.
•Inconvenience,lossofuseofthe
vehicle,commerciallossofany
kindincluding,butnotlimitedto,
consequentialorincidentaldamages.
•Anyvehicleinwhichtheodometer
hasbeenalteredordamagedsothat
mileagecannotbereadilydetermined.
18INTRODUCTION
THISW ARRANTYISEXPRESSL YINLIEUOFALLOTHERW ARRANTIES
ANDREPRESENT A TIONSORCONDITIONS,STA TUTORYOR
OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED
TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA
PARTICULARPURPOSE.
EmissionsControlSystemWarranty
Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheCaliforniacodeofregulations.
1TurbochargerAssembly
•VGTActuator
2ChargeAirCooler
•CACPipes(Airinletto/fromCAC)
•CACHoses
3EngineControlModule(ECM)
4Injectors
5EngineandV ehicleWireharness(
repairtocircuitsrelatedtoEmissions
WarrantableComponents)
6ExhaustGasRecirculation(EGR)
Mixer
7EGRCooler
8EGRV alveandEGRValveControl
9EGRPipes-EngineExhaustManifold
toEGRCooler
10EGRPipes-EGRCoolertoInlet
Manifold
11CrankcaseBreather
12CrankcaseSeparator
13CrankcaseTubingandHosesbefore
Separator
14AftertreatmentWiringHarness
15AftertreatmentControlModule(ACM)
16AftertreatmentDieselParticulateFilter
(DPF)Assembly
A.AftertreatmentDPFAssembly
withAftertreatmentDieselOxidation
Catalyst(DOC)
•AftertreatmentDoser
•DiffuserPipe(AftertreatmentFuel
DoserMounting)
•FuellinestoAftertreatmentFuel
Doser
•AftertreatmentFuelShutoffV alve
•AftertreatmentFuelPressureSensor
•EngineTurbochargerCompressor
BypassActuator(HeatMode)
•EngineTurbochargerCompressor
BypassActuatorSolenoid
•EngineExhaustGasT emperature
(EGT)Sensor
•AftertreatmentDPFIntake
TemperatureSensor
•AftertreatmentDPFOutlet
TemperatureSensor
•AftertreatmentDPFDifferential
PressureSensor
•AftertreamentDoserAirSupply
Regulator(ifapplicable),Supply
Lines,andFittings
B.ThermalRegenerationUnit(TRU)
•AftertreatmentDPFAirShutoff
Valve
•AftertreatmentDPFCombustion
AirValve
•AftertreatmentDPFAtomization
Module
•AftertreatmentDPFIgnitionCoil
INTRODUCTION19
•AftertreatmentDPFFuelControl
Valve
•AftertreatmentDPFIgnition
Electrode
•Nozzle
•EngineExhaustGasT emperature
(EGT)Sensor
•AftertreatmentDPFIntake
TemperatureSensor
•AftertreatmentDPFOutlet
TemperatureSensor
•AftertreatmentDPFSparkAssist
FlameTemperatureSensor
•AftertreatmentDPFDifferential
PressureSensor
17Sensors:
•CrankshaftPosition(CKP)
•CamshaftPosition(CMP)
•EngineCoolantTemperature(ECT)
•IntakeManifoldAirTemperature
•IntakeManifoldPressure(IMP)
•EGRTemperature
•AftertreatmentOutletNOx
•AftertreatmentIntakeNOx
•EGRDifferentialPressure
•AmbientAirTemperature(AA T)
18SCR
•AftertreatmentSelectiveCatalytic
Reduction(SCR)Catalyst
•AftertreatmentDieselExhaustFluid
(DEF)Pump
•AftertreatmentDEFDosing
AbsolutePressureSensor
•AftertreatmentDEFReturn
Valve
•AftertreatmentDEFDosingV alve
•AftertreatmentDEFTank
•AftertreatmentDEFTank
Heater/Sender
•AftertreatmentDEFTankHeater
•AftertreatmentDEFT ankHeater
Valve
•AftertreatmentDEFTank
TemperatureSensor
•AftertreatmentDEFLevelSensor
•AftertreatmentDEFHeatedLines
19.InstrumentCluster(Repairof
microprocessor,OBDMIL,RealTime
Clock,AftertreatmentDEFTankGauge
and,AftertreatmentDEFTankLowLevel
Indicator)
20.ExhaustGasPiping(from
TurbochargertoAftertreatmentSystem)
21.DataLinkConnector(DLC)
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