MACK LEU Operator's Manual

Mack

LEU Series

Mack® TerraProTM Series

(LEU Series)

Mack® TerraProTM Series

(LEU Series)

21394654

21394654 21394654

April 2010

Foreword

Thismanualcontainsinformationconcerningtheoperationand functionofthe MackLinkSystem.Theinformationinthismanual appliestovehiclesbuilt April2010andlater.Pleasekeepthismanual inthevehicleatalltimes.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay differslightlyfromtheactualvehicle.However,keycomponents addressedinthisdocumentarerepresentedasaccuratelyaspossible.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)and Mack Trucks Inc.,shouldbeinformedimmediatelyifyou believethatthevehiclehasadefectthatcouldcauseacrash,injury ordeath.

ContactNHTSAbycallingtheAutoSafetyHotlineat1(888) 327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation, Washington,DC20590,byTTYat1(800)424-9153,orvisittheir websiteatwww.nhtsa.dot.gov.

Mack Truck,Inc.

Greensboro,NCUSA

Ordernumber:PV776-21394654

Allrightsreserved.Nopartofthispublicationmaybereproduced, storedinretrievalsystem,ortransmittedinanyformsbyanymeans, electronic,mechanical,photocopying,recordingorotherwise,without thepriorwrittenpermissionof Mack Trucks, Inc.

Contents

INTRODUCTION............................................................................................................1

TOTHEOWNER..........................................................................................................1

InAppreciation..........................................................................................................1

AboutThisHandbook................................................................................................2

THEVEHICLE..............................................................................................................3

BasicConguration...................................................................................................3

VehicleManagementandControlSystem(V-MAC®).............................................3

COMPONENTIDENTIFICATION..............................................................................4

VINLocations............................................................................................................4

EngineIdentication..................................................................................................5

EngineInformationPlate...........................................................................................6

CleanIdleEngines.....................................................................................................7

TransmissionIdentication........................................................................................8

WARRANTYINFORMA TION..................................................................................10

AirBrakeSystem.....................................................................................................10

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................10

EmissionsControlSystemWarranty.......................................................................11

ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............13

FEDERALEMISSIONREQUIREMENTS............................................................14

EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................14

EmissionsControlSystemWarranty.......................................................................16

SERVICELITERATURE............................................................................................20

MACKClass8–ComponentsServiceManual.......................................................20

MACKClass8–CustomCollatedServiceManualonCD....................................20

CUSTOMERSERVICE..............................................................................................21

Call1-800-866-1177forMACKOneCall™...........................................................21

QuestionsandComplaints.......................................................................................21

Addresses.................................................................................................................22

AdditionalAssistance..............................................................................................22

REPORTINGSAFETYDEFECTS.............................................................................24

UnitedStates............................................................................................................24

Canada......................................................................................................................24

Mexico.....................................................................................................................24

EVENTDATARECORDINGDEVICES...................................................................25

SAFETYINFORMATION...........................................................................................26

SAFETYSTATEMENT..............................................................................................26

CERTIFICA TIONLABELS........................................................................................28

SafetyCerticationLabel........................................................................................28

ADVISORYLABELS.................................................................................................30

AdvisoryLabelLocations(OnV ehicle)..................................................................30

CABENTRY/EXIT.....................................................................................................39

Three-LimbContact.................................................................................................39

DriverSide...............................................................................................................41

PassengerSide.........................................................................................................43

SAFETYTIPSFORCOLDWEA THEROPERA TION.............................................44

DriverVisibility.......................................................................................................44

CabDoorSealsandKeyLocks...............................................................................45

OutsideMirrorHeater..............................................................................................45

AirHornSnowShield..............................................................................................46

FireExtinguisher(Optional)....................................................................................46

INSTRUMENTSANDCONTROLS...........................................................................47

CABINTERIOR—LEFT..........................................................................................47

CABINTERIOR—RIGHT.......................................................................................48

INSTRUMENTPANEL..............................................................................................49

Tell-T ales..................................................................................................................49

PanelArrangement...................................................................................................50

INSTRUMENTPANELGAUGELAYOUT..............................................................51

PanelsA,B,CandD...............................................................................................52

PanelE.....................................................................................................................53

PanelF.....................................................................................................................54

DPFINHIBITROADSPEEDLIMITING(RSL)...................................................62

CABCLIMATECONTROL.......................................................................................68

LIGHTCONTROLPANEL........................................................................................69

STEERINGCOLUMN................................................................................................70

CombinationStarterandElectricalSwitch..............................................................70

MISCELLANEOUSCONTROLS..............................................................................71

DomeLight..............................................................................................................71

AirHorn...................................................................................................................71

FreshAirVent..........................................................................................................72

AccessoryPowerOutlets.........................................................................................72

PRE-TRIPINSPECTIONANDDAILYMAINTENANCE......................................73

PRE-TRIP....................................................................................................................73

Pre-TripInspectionQuickList................................................................................73

OPERATION..................................................................................................................86

.....................................................................................................................................86

NewVehicleBreak-In..............................................................................................86

WINDSHIELDWASHERRESERVOIR....................................................................88

CABTILTOPERA TION.............................................................................................89

TiltingtheCab.........................................................................................................90

LoweringtheCab.....................................................................................................92

BleedingtheCabTiltSystem..................................................................................93

DOORS........................................................................................................................94

OpeningtheCabDoor.............................................................................................94

LockingtheCabDoor..............................................................................................94

Right-Side(Folding)Door.......................................................................................94

FoldingtheDoor......................................................................................................97

UnfoldingtheDoor................................................................................................100

SEATBEL TS.............................................................................................................102

SeatBeltOperation................................................................................................102

FasteningSeatBelt................................................................................................102

RIGHT-SIDERESTRAINT......................................................................................105

SEATADJUSTMENT...............................................................................................106

Right-SideFoldingSeat.........................................................................................106

AirSeat..................................................................................................................107

MIRRORSYSTEMS.................................................................................................109

MotoMirrorSystem..............................................................................................109

MACKENGINEINFORMATION...........................................................................112

PrecautionsandWarnings......................................................................................112

EngineModelDesignations...................................................................................113

CRUISECONTROLOPERATION..........................................................................114

SpeedControlSwitches.........................................................................................114

DisengagingCruiseControl...................................................................................115

MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................116

EngineBrakeSwitch..............................................................................................117

HowtheEngineBrakeisActivated.......................................................................117

CruiseControlwiththeMACKPowerLeash™EngineBrake.............................118

ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........119

OverFlatTerrain....................................................................................................119

DescendingaGrade...............................................................................................120

OnSlipperyRoadSurfaces....................................................................................122

BRAKEOPERATION...............................................................................................124

AirBrakeSystem...................................................................................................124

AutomaticSlackAdjusters....................................................................................125

ParkingBrakeSystem............................................................................................125

ParkingBrakeOperation........................................................................................126

Parking...................................................................................................................126

Anti-LockBrakeSystem(ABS)............................................................................127

AutomaticTractionControl(A TC)(IfEquipped).................................................130

WorkBrakeSystem...............................................................................................131

GOODDRIVINGHABITS.......................................................................................133

WeightRatings.......................................................................................................133

Instruments.............................................................................................................133

ShuttingDowntheEngine.....................................................................................133

GeneralObservation..............................................................................................133

STARTINGTHEVEHICLE.....................................................................................134

GeneralInformation...............................................................................................134

PushButtonStarters...............................................................................................134

AirStarters.............................................................................................................135

EngineWarm-Up...................................................................................................138

EngineIdling..........................................................................................................138

ShuttingDowntheEngine.....................................................................................139

COLDWEATHEROPERA TION.............................................................................141

ColdWeatherStartingTips....................................................................................141

EngineBlockHeaters............................................................................................142

MOVINGTHEVEHICLE—GENERALINFORMA TION...................................143

Braking...................................................................................................................143

EngineTemperature...............................................................................................143

TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................145

StatusLights..........................................................................................................148

TransmissionModuleLocation.............................................................................149

AXLES.......................................................................................................................150

RearAxlesOtherThanMACK.............................................................................150

MACKRearAxles.................................................................................................150

EngagingthePowerDividerLockout....................................................................151

ExtendedIdlingandAftertreatmentSystemConditioning.......................................154

Mack,US10EmissionsSolution.................................................................................155

DIESELPARTICULA TEFILTERS.........................................................................155

ExhaustAftertreatmentSystem.................................................................................158

SafetyInformation.................................................................................................159

ExhaustAftertreatmentSystemComponentsand................................................160

SelectiveCatalyticReduction(SCR)....................................................................160

DieselExhaustFluid(DEF)...................................................................................162

AftertreatmentDieselParticulateFilter(DPF)......................................................165

AftertreatmentControlModule(ACM).................................................................166

ExhaustAftertreatmentSystem............................................................................166

DriverWarningsandOnBoardDiagnostics(OBD).............................................172

OnBoardDiagnostics(OBD)................................................................................172

InstrumentCluster..................................................................................................173

MalfunctionIndicatorLamp(MIL).......................................................................174

AftertreatmentDEFTankLevel-DriverWarning&Inducement........................175

AftertreatmentDEFQuality-DriverWarning&Inducement..............................176

MisllingDieselorAftertreatmentDEFTanks.....................................................177

SCRTampering-DriverWarning&Inducement.................................................178

WarrantyandMaintenance....................................................................................179

ExhaustAftertreatmentSystemMaintenance........................................................179

EngineMaintenanceIntervals................................................................................179

MAINTENANCEANDLUBRICATION..................................................................180

MAINTENANCEINTRODUCTION.......................................................................180

TURBOCHARGER...................................................................................................181

CLEANINGYOURVEHICLE.................................................................................182

ExteriorWashing...................................................................................................182

CabandHood........................................................................................................184

Chassis...................................................................................................................184

CabInterior............................................................................................................184

Waxing...................................................................................................................185

Polishing................................................................................................................185

WinterW arnings....................................................................................................185

TOWING...................................................................................................................186

ENGINEOILLEVELCHECK.................................................................................188

PowerSteeringReservoir......................................................................................189

FUELTANK..............................................................................................................190

FuelTankCap........................................................................................................190

FUELING..................................................................................................................191

BioDiesel................................................................................................................192

B5ApprovalForMACKUS2010CertiedProducts..........................................192

COOLINGSYSTEM.................................................................................................194

CoolantLevelCheck..............................................................................................194

DrainingtheCoolingSystem.................................................................................195

RellingtheCoolingSystem.................................................................................195

ProtectingtheCoolingSystem..............................................................................196

CoolingSystemMaintenance................................................................................197

AccessoryDriveBeltRouting...............................................................................198

HEADLIGHTS..........................................................................................................199

BulbReplacement..................................................................................................199

WHEELS...................................................................................................................199

WheelInspection...................................................................................................199

Tires.......................................................................................................................200

BATTERY..................................................................................................................203

Jump-StartingEngine.............................................................................................203

ELECTRICAL...........................................................................................................205

CircuitBreakerandRelayPanels..........................................................................205

ElectricalGrease....................................................................................................209

CircuitProtectionCharts........................................................................................210

METRICCONVERSIONS.........................................................................................212

METRICCONVERSIONS.......................................................................................212

SafetyInformation

IMPORTANT:Beforedrivingthis vehicle,becertainthatyouhaveread andthatyoufullyunderstandeachand everystepofthedrivingandhandling informationinthismanual.Becertain thatyoufullyunderstandandfollowall safetywarnings.

ITISIMPORT ANTTHA TTHE FOLLOWINGINFORMA TIONBE READ,UNDERSTOODANDALW AYS 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.

INTRODUCTION1

TOTHEOWNER

InAppreciation

ThankyouforbuyingaMackK®vehicle.Withpropercareandmaintenance, yournewMack®T erraPro™LEUmodelwillhelpyougainacompetitiveedge withitsfuel-efcientdrivetraincombinations,lowmaintenance,extended serviceintervalsand,eventually ,goodresalevalue.

TheMack®TerraPro™LEUmodelisavailableforawiderangeof applications.Becauseofthisversatility ,drivetrainsandcomponentsvaryand operatinginstructionsmaydifferfromonemodeltoanother.Whileevery efforthasbeenmadetocoverallcurrentarrangements,donothesitateto consultyourMACKdistributorifaquestionarises.Honest,personalservice isstandardwitheveryMACKsale.

CAUTION

MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.

We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack® TerraPro™LEUmodel,andthatyouseemanyyearsoftrouble-freedriving.

Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations applicableatthetimeofmanufacture.

2INTRODUCTION

AboutThisHandbook

ThishandbookisreferredtoastheMack®T erraPro™LEUSeriesOperator’s Handbook.ItcoversallMack®T erraPro™LEUmodels.Itsidentication

numberis21394654.Keepthishandbookwiththevehicleatalltimesto ensurethateachownerand/oroperatorwillhaveaccesstoallpertinent informationrelatingtotheoperationandhandlingofthisvehicle.

Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation concerningthedailyoperationofthisvehicle.Pleasereaditthoroughly; payparticularattentiontoadvisorylabelsthathavebeenincludedtodraw attentiontoimportantissuesofoperatorsafetyandoverallperformance.

Informationandillustrationsinthishandbookarebasedonthelatest productionusageatthetimeofprintingandaresubjecttochangewithout priornotice.

Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual beginningwith“MAINTENANCEINTRODUCTION”,page180.Forfurther information,refertotheMaintenanceandLubricationManual(21394653).Other importantinformationcanbefoundintheEmissionControlSystemsforMACK DieselEngineManual(21351488).

INTRODUCTION3

THEVEHICLE

BasicConguration

TheMack®T erraPro™LEUmodelhasalow-entry ,cab-forward-style operatorscompartment.One-stepentryanddualsteering/braking arrangementsmakeitaverypopularandpracticalvehicleforrefuse managementcompanies.

VehicleManagementandControlSystem (V-MAC®)

TheVehicleManagementandControlSystem(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

TheV ehicleIdenticationNumber(VIN)isdisplayedintwolocations(aframe railstampingandalabel).The17-digitVINmustbeidenticalinbothlocations.

TheVINframestampingislocatedontherightoutsideframerailandthe leftinsideframerail.

C0029554

TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.

C0028941

INTRODUCTION5

EngineIdentication

OntheMACKMPengines,theengineserialnumberisstampedontheleft sideoftheengineblock,belowtheinletmanifold.

C0028943

6INTRODUCTION

EngineInformationPlate

IncompliancewithFederalandCaliforniaemissionrequirements,an engineinformationlabelisafxedtoallMACKdieselengines.Thislabel, whichislocatedonthecylinderheadcoveratthefrontoftheengine,gives basicengineidenticationinformation(enginemodel,serialnumber,etc.), advertisedhorsepoweratratedspeed,emissionsregulationstowhichthe engineconformsandinletandexhaustvalvelashsettings.Examplesofthe 49stateEPAapproved,and50stateEPAandCaliforniaapprovedengine identicationlabelsaregivenbelow.

W2040455

EngineIdenticationLabel-49StateEPAApprovedEngine

withoutCalifornia"CleanIdle"

EngineIdenticationLabel-50StateEPAApprovedEngine

withCalifornia"CleanIdle"

W2040456

INTRODUCTION7

CleanIdleEngines

TheCaliforniaAirResourcesBoard(ARB)requiresthat2008andlatermodel yearvehiclesbeequippedwithengineshavingtamper-resistantsoftware whichlimitsthetimeatwhichtheenginecanidleatspeedsabovelowidle (550–700rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idle timewillbelimitedtoveminutes,afterwhichtheenginewillrevertback tolowidle.V ehiclesequippedwithaCleanIdleengineareidentiedbya labelwhichisafxedtothelowerportionofthedriver’ssidedooroncab-over models(LEU).

CleanIdleEngineLabel

W2056289

8INTRODUCTION

TransmissionIdentication

TheAllisonRDSandHStransmissionidenticationplateislocatedonthe rearrightsideofthemaincase,nearthelowerend.

C0029555

TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside ofthehousing.

C0028950

TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe axlehousingtowardthecarrier.

C0028951

INTRODUCTION9

TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft sideoftheforwardcarrier,andthetopoftherearcarrier.

C0028952

TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof therearaxlehousing,nexttothecarrier.

C0028953

TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof theforwardcarrier,andthetopoftherearcarrier.

C0028954

10INTRODUCTION

WARRANTYINFORMATION

ThischassisisequippedwithaUS’10emissioncompliantengineandan exhaustaftertreatmentsystem(DieselParticulateFilter).UseofUltraLow SulfurDiesel(ULSD)fuelandEO-OPremiumPlus(orVDS-4)specication highperformancedieselengineoilisrequiredinthisvehicle.

Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand aftertreatmentsystemwarranty.

AirBrakeSystem

TheMACKStandardVehicleWarrantyappliestotheairbrakesystem,as setforthintheWarranty,butonlyiftheairbrakesystemhasnotbeen subjectedtounauthorizedadditions,deletionsormodications.Ifanysuch unauthorizedadditions,deletionsormodicationsareperformed,Mack Trucks,Inc.disclaimsanyandallliabilityforanylossordamagearisingoutof amalfunctionoftheairbrakesystem.

Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.

Tractorairsystemsaredesignedforoperationasatractoronly,andtruckair systemsaredesignedtobeoperatedasatruckonly .Ifatractorisgoingtobe convertedforoperationasatruck,theairbrakesystemmustberecongured tothatofatruck.Conversely,ifatruckisgoingtobeconvertedforoperation asatractor,theairbrakesystemmustbereconguredtothatofatractor. ConsultyourlocalMACKdistributorforadditionalinformation.

Ifanyunauthorizedadditions,deletionsormodicationsaremadetoany portionoftheairbrakesystemwhichisrequiredbyFederalMotorVehicle SafetyStandards,MackTrucks,Inc.makesnorepresentationastoconformity withtheStandards.

Forcompletewarrantyinformation,refertothePedigreedProtectionPlan providedwitheachvehicle.

ENGINEGASEOUSEMISSIONCONTROL SYSTEMS

WARRANTYMAINTENANCE

Note:Foremissioncontrolsystems informationonenginesotherthanMACK, refertotheenginevendor’spublication

INTRODUCTION11

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY

MackTrucks,Inc.warrantstheEmission ControlSystemsoneachnewMack dieselengineinanewMackTruckto complywithallUnitedStatesFederal andCanadianemissionsregulations applicableatthetimeofmanufactureof theengine,andtobefreefromdefects inmaterialandworkmanshipunder normaluseandserviceupto60months, or160934km(100,000miles),which everoccursrst,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.

QualicationsandLimitations:

Note:NotcoveredbytheEmissions ControlSystemsW arranty:

•Malfunctionscausedbymisuse,

improperadjustments,modication, alteration,tampering,disconnection, improperorinadequatemaintenance anduseofimproperdieselfuelorDEF .

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

THISW ARRANTYISEXPRESSL YINLIEUOFALLOTHERW ARRANTIES ANDREPRESENTATIONSORCONDITIONS,STA TUTORYOR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA PARTICULARPURPOSE.

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACHoses

3EngineControlModule(ECM)

4Injectors

•CACPipes(Airinletto/fromCAC)

12INTRODUCTION

5EngineandVehicleWireharness(

repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRValveandEGRV alveControl

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

•DischargeRecirculationValve

(DRV)(HeatMode)

•DischargeRecirculationValve

(DRV)Solenoid

•EngineTurbochargerCompressor

BypassActuator(HeatMode)

•EngineTurbochargerCompressor

BypassActuatorSolenoid

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFCombustion

AirControlV alve

•AftertreatmentDPFCombustion

AirV alve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

INTRODUCTION13

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AA T)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFTank

Heater/Sender

ENGINEGASEOUSEMISSIONSCONTROL SYSTEMWARRANTY

•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)

Theemissionwarrantyforthediesel particulatelter(DPF)andSCRSystem coversdefectsinworkmanshiponly. Normalmaintenance,suchascleaning ashfromthelteratregularmaintenance 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.

14INTRODUCTION

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.

4Anypersonwhooperatesaeetof

Note:Forspecicsoftheprohibited vehicle/enginemodicationsreferto 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’SW ARRANTY COVERAGE:

Ifanemission-relatedpartofyourengine isdefective,thepartwillberepairedor replacedbyMackTrucks,Inc.Thisis youremissioncontrolsystemDEFECTS WARRANTY .

OWNER’SWARRANTYRESPONSIBILITIES:

INTRODUCTION15

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 modications. Ifyouhaveanyquestionsregarding yourwarrantyrightsandresponsibilities, youshouldcontacttheMackTrucks, Inc.WarrantyActivitiesP .O.Box26259, Greensboro,NC27402,ortheCalifornia AirResourcesBoardat9480Telstar Avenue,ElMonte,California91731.

(Applicableonlytovehiclesand/or enginescertiedforsaleandregistered

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.

QualicationsandLimitations:

NotcoveredbytheEmissionsControl SystemsW arranty:

•Malfunctionscausedbymisuse,

improperadjustments,modication, alteration,tampering,disconnection, improperorinadequatemaintenance anduseofimproperdieselfuelorDEF .

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

16INTRODUCTION

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheCaliforniacodeofregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandV ehicleWireharness

(repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRValveandEGRV alveControl

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

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFAirShutoff

Valve

•AftertreatmentDPFCombustion

AirV alve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

INTRODUCTION17

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasTemperature

(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

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)

18INTRODUCTION

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY—Continued

CAUTION

Anyunauthorizedadjustmentstothe emissioncontrolcomponentscancause severedamagetotheengine.

establishment,orbytheowner,usingany replacementpart,withinthelimitations ofparagraphs3and4inthissection.An emergencyconditionexistsunderthis sectionif,after30days,repairshave notbeencompletedorpartsarenotyet available.MACKwillreimbursethe ownerforsuchrepairsthatarecovered underthiswarranty ,includingdiagnosis, nottoexceedMACK’ssuggestedretail priceforpartsreplacedandlaborcharges basedonMACK’srecommendedtime allowanceandgeographicallyappropriate hourlylaborrate.Replacedpartsandpaid invoicesmustbepresentedataMACK facilityasaconditionofreimbursementfor emergencyrepairsperformedelsewhere.

CAUTION

Intheeventthatdamageresultsfrom unauthorizedadjustmentstoany emissioncontrolsystemcomponents, asevidencedbysettingsotherthanas specied,orbrokenfastenerseals,the costofrepairingsuchdamageWILL NOTBECOVEREDunderwarranty

1.RepairsbyMACKDealers,

Sub-DealersandServiceDealers

RepairscoveredbytheCalifornia EmissionControlSystemsW arrantywill beperformedbyanyauthorizedMACK repairfacilityathisplaceofbusinesswith nochargeforpartsandlabor(including diagnosis),usingMACKpartsforanypart oftheemissioncontrolsystemscovered bythiswarrantyandfounddefective.

2.InanEmergency Inanemergency,whereanauthorized MACKfacilityisnotavailable,repairs maybeperformedatanyavailableservice

3.RepairsbyNon-MACKFacilities Ownersmayelecttohavemaintenance, replacement,orrepairofemissioncontrol systemsperformedbyanyrepairfacility, andmayelecttousepartsotherthan MACKpartswithoutinvalidatingthe warrantyonothercomponents,butthe costofsuchserviceorpartswillnotbe coveredbyMACKunderitswarranty.

4.UseofNon-MACKParts Useofreplacementpartswhicharenotthe equivalentofMACKpartsmayimpairthe effectivenessofemissioncontrolsystems. IfotherthanMACKpartsareused,the

INTRODUCTION19

ownershouldobtainassurancesthatsuch partsarewarrantedbytheirmanufacturer tobetheequivalentofMACKparts inperformanceanddurability.MACK assumesnoliabilityunderthiswarranty withrespecttopartsotherthanMACK parts;however,theuseofnon-MACK partsdoesnotinvalidatethewarrantyon othercomponentsunlessnon-MACKparts causedamagetowarrantedparts.

5.MaintenanceandMaintenance

Records

Thevehicleownerisresponsibleforthe performanceofallrequiredmaintenance speciedinthismanual.MACKwillnot denyawarrantyclaimsolelybecausethere isnorecordofmaintenance;however, MACKmaydenyawarrantyclaimif failuretoperformrequiredmaintenance resultsinthefailureofawarrantedpart. Receiptsorotherrecordscoveringthe performanceofscheduledmaintenance shouldberetainedtoanswerquestions thatmayariseconcerningmaintenance. Maintenancerecordsshouldbetransferred tosubsequentownersifthevehicleissold.

6.ItemsNotCoveredbytheEmission

ControlSystemsWarranty

•Malfunctionscausedbymisuse,

improperadjustments,modication, alteration,tampering,disconnection, improperorinadequatemaintenance anduseofimproperdieselfuel.

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

7.CustomerAssistance MACKwishestoassurethattheCalifornia EmissionControlSystemsWarrantyis properlyadministered.Intheeventthat ownersdonotreceivethewarrantyservice towhichtheybelievetheyareentitled undertheCaliforniaEmissionControl SystemsW arranty ,theyshouldcontact thenearestMACKRegionalOfcefor assistance.Theaddressandtelephone numberforeachRegionalOfceare intheMACKDirectoryofSales,Parts andServiceCenters.Ownersinneed ofadditionalassistanceorinformation concerningtheCaliforniaEmission ControlSystemsW arrantymayalso contact:

MackTrucks,Inc.

WarrantyActivities

P.O.Box26259

Greensboro,NC27402

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