MACK LEU Operator's Manual

Mack® TerraProTM Series

(LEU Series)

Series LEU®Mack

Mack® TerraProTM Series

(LEU Series)

21394654 © Mack Trucks, Inc. 2010

Printed in U.S.A.

21394654

21394654 April 2010

Foreword

This manual contains information concerning the operation and function of the Mack Link System. The information in this manual appliestovehiclesbuilt April 2010 and later. Please keep this manual in the vehicle at all times.

Note: Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle. However, key components addressed in this document are represented as accurately as possible.

The National Highway Traffic Safety Administration (NHTSA) and Mack Trucks Inc., should be informed immediately if you

believe that the vehicle has a defect that could cause a crash, injury or death.

Contact NHTSA by calling the Auto Safety Hotline at 1 [phone], by writing to NHTSA, U.S. Department of Transportation, Washington, DC 20590, by TTY at 1 [phone], or visit their website at www.nhtsa.dot.gov.

Mack Truck, Inc.

Greensboro, NC USA

Order number: PV776-21394654

©2010 Mack Trucks, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means,

electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Mack Trucks, Inc.

Contents
INTRODUCTION............................................................................................................	1
TO THE OWNER..........................................................................................................	1
In Appreciation..........................................................................................................	1
About This Handbook................................................................................................	2
THE VEHICLE..............................................................................................................	3
Basic Configuration ...................................................................................................	3
Vehicle Management and Control System (V-MAC®).............................................	3
COMPONENT IDENTIFICATION..............................................................................	4
VIN Locations............................................................................................................	4
Engine Identification..................................................................................................	5
Engine Information Plate...........................................................................................	6
Clean Idle Engines.....................................................................................................	7
Transmission Identification........................................................................................	8
WARRANTY INFORMATION..................................................................................	10
Air Brake System.....................................................................................................	10
ENGINE GASEOUS EMISSION CONTROL SYSTEMS ....................................	10
Emissions Control System Warranty.......................................................................	11
ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY.............	13
FEDERAL EMISSION REQUIREMENTS............................................................	14
EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA..................	14
Emissions Control System Warranty.......................................................................	16
SERVICE LITERATURE............................................................................................	20
MACK Class 8 –Components Service Manual .......................................................	20
MACK Class 8 – Custom Collated Service Manual on CD....................................	20
CUSTOMER SERVICE ..............................................................................................	21
Call 1-800-866-1177 for MACK OneCall™...........................................................	21
Questions and Complaints.......................................................................................	21
Addresses.................................................................................................................	22
Additional Assistance..............................................................................................	22
REPORTING SAFETY DEFECTS.............................................................................	24
United States............................................................................................................	24
Canada......................................................................................................................	24
Mexico.....................................................................................................................	24
EVENT DATA RECORDING DEVICES...................................................................	25
SAFETY INFORMATION...........................................................................................	26
SAFETY STATEMENT ..............................................................................................	26
CERTIFICATION LABELS........................................................................................	28
Safety Certification Label........................................................................................	28
ADVISORY LABELS.................................................................................................	30
Advisory Label Locations (On Vehicle)..................................................................	30
CAB ENTRY/EXIT.....................................................................................................	39
Three-Limb Contact.................................................................................................	39
Driver Side...............................................................................................................	41
Passenger Side .........................................................................................................	43
SAFETY TIPS FOR COLD WEATHER OPERATION.............................................	44
Driver Visibility.......................................................................................................	44

Cab Door Seals and Key Locks...............................................................................	45
Outside Mirror Heater..............................................................................................	45
Air Horn Snow Shield..............................................................................................	46
Fire Extinguisher (Optional)....................................................................................	46
INSTRUMENTS AND CONTROLS...........................................................................	47
CAB INTERIOR — LEFT..........................................................................................	47
CAB INTERIOR — RIGHT .......................................................................................	48
INSTRUMENT PANEL..............................................................................................	49
Tell-Tales..................................................................................................................	49
Panel Arrangement...................................................................................................	50
INSTRUMENT PANEL GAUGE LAYOUT..............................................................	51
Panels A, B, C and D...............................................................................................	52
Panel E.....................................................................................................................	53
Panel F .....................................................................................................................	54
DPF INHIBIT ROAD SPEED LIMITING (RSL)...................................................	62
CAB CLIMATE CONTROL.......................................................................................	68
LIGHT CONTROL PANEL........................................................................................	69
STEERING COLUMN................................................................................................	70
Combination Starter and Electrical Switch..............................................................	70
MISCELLANEOUS CONTROLS..............................................................................	71
Dome Light..............................................................................................................	71
Air Horn...................................................................................................................	71
Fresh Air Vent..........................................................................................................	72
Accessory Power Outlets.........................................................................................	72
PRE-TRIP INSPECTION AND DAILY MAINTENANCE......................................	73
PRE-TRIP....................................................................................................................	73
Pre-Trip Inspection Quick List ................................................................................	73
OPERATION..................................................................................................................	86
.....................................................................................................................................	86
New Vehicle Break-In..............................................................................................	86
WINDSHIELD WASHER RESERVOIR....................................................................	88
CAB TILT OPERATION.............................................................................................	89
Tilting the Cab .........................................................................................................	90
Lowering the Cab.....................................................................................................	92
Bleeding the Cab Tilt System..................................................................................	93
DOORS........................................................................................................................	94
Opening the Cab Door.............................................................................................	94
Locking the Cab Door..............................................................................................	94
Right-Side (Folding) Door.......................................................................................	94
Folding the Door......................................................................................................	97
Unfolding the Door................................................................................................	100
SEAT BELTS.............................................................................................................	102
Seat Belt Operation................................................................................................	102
Fastening Seat Belt ................................................................................................	102
RIGHT-SIDE RESTRAINT......................................................................................	105

SEAT ADJUSTMENT...............................................................................................	106
Right-Side Folding Seat.........................................................................................	106
Air Seat..................................................................................................................	107
MIRROR SYSTEMS.................................................................................................	109
Moto Mirror System ..............................................................................................	109
MACK ENGINE INFORMATION...........................................................................	112
Precautions and Warnings......................................................................................	112
Engine Model Designations...................................................................................	113
CRUISE CONTROL OPERATION..........................................................................	114
Speed Control Switches.........................................................................................	114
Disengaging Cruise Control...................................................................................	115
MACK POWERLEASH™ ENGINE BRAKE (IF EQUIPPED)..............................	116
Engine Brake Switch..............................................................................................	117
How the Engine Brake is Activated.......................................................................	117
Cruise Control with the MACK PowerLeash™ Engine Brake.............................	118
ON THE ROAD WITH THE MACK POWERLEASH™ ENGINE BRAKE.........	119
Over Flat Terrain....................................................................................................	119
Descending a Grade...............................................................................................	120
On Slippery Road Surfaces....................................................................................	122
BRAKE OPERATION...............................................................................................	124
Air Brake System...................................................................................................	124
Automatic Slack Adjusters ....................................................................................	125
Parking Brake System............................................................................................	125
Parking Brake Operation........................................................................................	126
Parking...................................................................................................................	126
Anti-Lock Brake System (ABS)............................................................................	127
Automatic Traction Control (ATC) (If Equipped).................................................	130
Work Brake System ...............................................................................................	131
GOOD DRIVING HABITS.......................................................................................	133
Weight Ratings.......................................................................................................	133
Instruments.............................................................................................................	133
Shutting Down the Engine.....................................................................................	133
General Observation..............................................................................................	133
STARTING THE VEHICLE .....................................................................................	134
General Information...............................................................................................	134
Push Button Starters...............................................................................................	134
Air Starters.............................................................................................................	135
Engine Warm-Up...................................................................................................	138
Engine Idling..........................................................................................................	138
Shutting Down the Engine.....................................................................................	139
COLD WEATHER OPERATION.............................................................................	141
Cold Weather Starting Tips....................................................................................	141
Engine Block Heaters ............................................................................................	142
MOVING THE VEHICLE — GENERAL INFORMATION...................................	143
Braking...................................................................................................................	143
Engine Temperature...............................................................................................	143
TRANSMISSION SHIFTING INSTRUCTIONS.....................................................	145

Status Lights ..........................................................................................................	148
Transmission Module Location .............................................................................	149
AXLES.......................................................................................................................	150
Rear Axles Other Than MACK.............................................................................	150
MACK Rear Axles.................................................................................................	150
Engaging the Power Divider Lockout....................................................................	151
Extended Idling and Aftertreatment System Conditioning .......................................	154
Mack, US10 Emissions Solution.................................................................................	155
DIESEL PARTICULATE FILTERS .........................................................................	155
Exhaust Aftertreatment System.................................................................................	158
Safety Information.................................................................................................	159
Exhaust Aftertreatment System Components and ................................................	160
Selective Catalytic Reduction (SCR) ....................................................................	160
Diesel Exhaust Fluid (DEF)...................................................................................	162
Aftertreatment Diesel Particulate Filter (DPF)......................................................	165
Aftertreatment Control Module (ACM).................................................................	166
Exhaust Aftertreatment System ............................................................................	166
Driver Warnings and On Board Diagnostics (OBD) .............................................	172
On Board Diagnostics (OBD)................................................................................	172
Instrument Cluster..................................................................................................	173
Malfunction Indicator Lamp (MIL).......................................................................	174
Aftertreatment DEF Tank Level - Driver Warning & Inducement........................	175
Aftertreatment DEF Quality - Driver Warning & Inducement..............................	176
Misfilling Diesel or Aftertreatment DEF Tanks.....................................................	177
SCR Tampering - Driver Warning & Inducement.................................................	178
Warranty and Maintenance....................................................................................	179
Exhaust Aftertreatment System Maintenance........................................................	179
Engine Maintenance Intervals................................................................................	179
MAINTENANCE AND LUBRICATION..................................................................	180
MAINTENANCE INTRODUCTION.......................................................................	180
TURBOCHARGER...................................................................................................	181
CLEANING YOUR VEHICLE.................................................................................	182
Exterior Washing ...................................................................................................	182
Cab and Hood ........................................................................................................	184
Chassis...................................................................................................................	184
Cab Interior............................................................................................................	184
Waxing...................................................................................................................	185
Polishing ................................................................................................................	185
Winter Warnings....................................................................................................	185
TOWING ...................................................................................................................	186
ENGINE OIL LEVEL CHECK.................................................................................	188
Power Steering Reservoir ......................................................................................	189
FUEL TANK..............................................................................................................	190
Fuel Tank Cap........................................................................................................	190
FUELING ..................................................................................................................	191

BioDiesel................................................................................................................	192
B5 Approval For MACK US 2010 Certified Products..........................................	192
COOLING SYSTEM.................................................................................................	194
Coolant Level Check..............................................................................................	194
Draining the Cooling System.................................................................................	195
Refilling the Cooling System.................................................................................	195
Protecting the Cooling System ..............................................................................	196
Cooling System Maintenance................................................................................	197
Accessory Drive Belt Routing...............................................................................	198
HEADLIGHTS..........................................................................................................	199
Bulb Replacement..................................................................................................	199
WHEELS...................................................................................................................	199
Wheel Inspection ...................................................................................................	199
Tires .......................................................................................................................	200
BATTERY..................................................................................................................	203
Jump-Starting Engine.............................................................................................	203
ELECTRICAL...........................................................................................................	205
Circuit Breaker and Relay Panels..........................................................................	205
Electrical Grease....................................................................................................	209
Circuit Protection Charts........................................................................................	210
METRIC CONVERSIONS.........................................................................................	212
METRIC CONVERSIONS .......................................................................................	212

Safety Information

IMPORTANT: Before driving this vehicle, be certain that you have read and that you fully understand each and every step of the driving and handling information in this manual. Be certain that you fully understand and follow all safety warnings.

IT IS IMPORTANT THAT THE FOLLOWING INFORMATION BE READ, UNDERSTOOD AND ALWAYS FOLLOWED.

The following types of advisories are used throughout this manual:

DANGER

Danger indicates an unsafe practice that could result in serious personal injury or death. A danger advisory banner is in white type on a black background with a black border.

WARNING

Warning indicates an unsafe practice that could result in personal injury. A warning advisory banner is in black typeona gray backgroundwitha black border.

CAUTION

Cautionindicatesanunsafepracticethat could result in damage to the product. A caution advisory is in black type on a white background with a black border.

Note: Noteindicatesaprocedure,practice, orconditionthatmustbefollowedinorder for the vehicle or component to function in the manner intended.

INTRODUCTION 1

TO THE OWNER

In Appreciation

Thank you for buying a MackK® vehicle. With proper care and maintenance, your new Mack® TerraPro™ LEU model will help you gain a competitive edge with its fuel-efficient drivetrain combinations, low maintenance, extended service intervals and, eventually, good resale value.

The Mack® TerraPro™ LEU model is available for a wide range of applications. Because of this versatility, drivetrains and components vary and operating instructions may differ from one model to another. While every effort has been made to cover all current arrangements, do not hesitate to consult your MACK distributor if a question arises. Honest, personal service is standard with every MACK sale.

CAUTION

Mack Trucks, Inc. would like to point out the important role that the driver plays in thelifeofthevehicle. Onlytrainedandinformeddriversshouldoperatethisvehicle.

We, at Mack Trucks, Inc., hope that you will be happy with your new Mack® TerraPro™ LEU model, and that you see many years of trouble-free driving.

This vehicle was built to conform to all federal standards and regulations applicable at the time of manufacture.

2 INTRODUCTION

About This Handbook

This handbook is referred to as the Mack® TerraPro™ LEU Series Operator’s Handbook. It covers all Mack® TerraPro™ LEU models. Its identification number is 21394654. Keep this handbook with the vehicle at all times to ensure that each owner and/or operator will have access to all pertinent information relating to the operation and handling of this vehicle.

This handbook was prepared to provide the driver with all relevant information concerning the daily operation of this vehicle. Please read it thoroughly; pay particular attention to advisory labels that have been included to draw attention to important issues of operator safety and overall performance.

Information and illustrations in this handbook are based on the latest production usage at the time of printing and are subject to change without prior notice.

Note: Basic maintenance and lubrication procedures are found in this manual beginning with “MAINTENANCE INTRODUCTION”, page 180. For further information, refer to the Maintenance and Lubrication Manual (21394653). Other important information can be found in the Emission Control Systems for MACK Diesel Engine Manual (21351488).

INTRODUCTION 3

THE VEHICLE

Basic Configuration

The Mack® TerraPro™ LEU model has a low-entry, cab-forward-style operators compartment. One-step entry and dual steering/braking arrangements make it a very popular and practical vehicle for refuse management companies.

Vehicle Management and Control System

(V-MAC®)

The Vehicle Management and Control System (V-MAC) is an electronic control system that manages engine and vehicle functions. In addition, the DataMax™ portion of V-MAC monitors and stores a variety of information (i.e., maintenance schedules, overspeed logs, fault tables, trip summaries).

For a complete description of the V-MAC IV system, refer to the applicable V-MAC® Operator’s Guide, which is supplied with the vehicle.

Additional information concerning service, diagnostics, programming and vendor equipment interface application is available from the Mack Trucks, Inc. Service Publications Department. Contact your local MACK dealer for details.

WARNING

Never cut into the V-MAC system wire harness to power additional equipment. If such equipment is to be installed, contact your MACK dealer for assistance.

4 INTRODUCTION

COMPONENT IDENTIFICATION

Locate the following serial numbers and write them in the boxes provided next to each illustration.

VIN Locations

The Vehicle Identification Number (VIN) is displayed in two locations (a frame rail stamping and a label). The 17-digit VIN must be identical in both locations.

The VIN frame stamping is located on the right outside frame rail and the left inside frame rail.

C0029554

The VIN label is located on the inside door frame below the driver seat.

C0028941

INTRODUCTION 5

Engine Identification

On the MACK MP engines, the engine serial number is stamped on the left side of the engine block, below the inlet manifold.

C0028943

6 INTRODUCTION

Engine Information Plate

In compliance with Federal and California emission requirements, an engine information label is affixed to all MACK diesel engines. This label, which is located on the cylinder head cover at the front of the engine, gives basic engine identification information (engine model, serial number, etc.), advertised horsepower at rated speed, emissions regulations to which the engine conforms and inlet and exhaust valve lash settings. Examples of the 49 state EPA approved, and 50 state EPA and California approved engine identification labels are given below.

W2040455

Engine Identification Label - 49 State EPA Approved Engine without California "Clean Idle"

W2040456

Engine Identification Label - 50 State EPA Approved Engine with California "Clean Idle"

INTRODUCTION 7

Clean Idle Engines

The California Air Resources Board (ARB) requires that 2008 and later model year vehicles be equipped with engines having tamper-resistant software which limits the time at which the engine can idle at speeds above low idle (550–700 rpm). At speeds above low idle, and without a PTO engaged, idle time will be limited to five minutes, after which the engine will revert back

to low idle. Vehicles equipped with a Clean Idle engine are identified by a label which is affixed to the lower portion of the driver’s side door on cab-over models (LEU).

W2056289

Clean Idle Engine Label

8 INTRODUCTION

Transmission Identification

The Allison RDS and HS transmission identification plate is located on the rear right side of the main case, near the lower end.

C0029555

The MACK carrier assembly serial number is located on the front right side of the housing.

C0028950

The Eaton® Spicer® rear axle serial number is located on the rear of the axle housing toward the carrier.

C0028951

INTRODUCTION 9

The Eaton® Spicer® carrier assembly serial number is located on the left side of the forward carrier, and the top of the rear carrier.

C0028952

The MERITOR rear axle identification tag is located on the left or right rear of the rear axle housing, next to the carrier.

C0028953

The MERITOR carrier assembly serial number is located on the left side of the forward carrier, and the top of the rear carrier.

C0028954

10 INTRODUCTION

WARRANTY INFORMATION

This chassis is equipped with a US’10 emission compliant engine and an exhaust aftertreatment system (Diesel Particulate Filter). Use of Ultra Low Sulfur Diesel (ULSD) fuel and EO-O Premium Plus (or VDS-4) specification high performance diesel engine oil is required in this vehicle.

Note: Use of improper or unapproved fuel or engine oil will void the engine and aftertreatment system warranty.

Air Brake System

The MACK Standard Vehicle Warranty applies to the air brake system, as set forth in the Warranty, but only if the air brake system has not been subjected to unauthorized additions, deletions or modifications. If any such unauthorized additions, deletions or modifications are performed, Mack Trucks, Inc. disclaims any and all liability for any loss or damage arising out of a malfunction of the air brake system.

The air brake system was designed and built to conform to all applicable federal motor vehicle safety standards in effect at the time of manufacture.

Tractor air systems are designed for operation as a tractor only, and truck air systems are designed to be operated as a truck only. If a tractor is going to be converted for operation as a truck, the air brake system must be reconfigured to that of a truck. Conversely, if a truck is going to be converted for operation as a tractor, the air brake system must be reconfigured to that of a tractor.

Consult your local MACK distributor for additional information.

If any unauthorized additions, deletions or modifications are made to any portion of the air brake system which is required by Federal Motor Vehicle Safety Standards, Mack Trucks, Inc. makes no representation as to conformity with the Standards.

For complete warranty information, refer to the Pedigreed Protection Plan provided with each vehicle.

ENGINE GASEOUS EMISSION CONTROL SYSTEMS

WARRANTY MAINTENANCE

Note: For emission control systems information on engines other than MACK, refer to the engine vendor’s publication

INTRODUCTION 11

ENGINE GASEOUS EMISSION CONTROL SYSTEMS WARRANTY

Mack Trucks, Inc. warrants the Emission Control Systems on each new Mack diesel engine in a new Mack Truck to comply with all United States Federal and Canadian emissions regulations applicable at the time of manufacture of the engine, and to be free from defects in material and workmanship under normal use and service up to 60 months, or 160934 km (100,000 miles), which ever occurs first, provided that all Mack Trucks, Inc. maintenance requirements are followed as described in this manual. All warranty periods are calculated from the date-in-service of the new vehicle.

The repair or replacement of defective parts will be made without charge for the cost of parts and if repairs are made at an authorized Mack Trucks, Inc. dealership, there will be no charge for labor. Mack Trucks, Inc.’s obligation under this warranty is limited to the repair or replacement, at Mack Trucks, Inc.’s option, of any part(s) of the Emission Control Systems of such engine and/or vehicle found to be defective upon examination by Mack Trucks, Inc. and provided that such part(s) were returned to MackTrucks,Inc. oritsnearestauthorized Dealer within a reasonable period of time.

Qualifications and Limitations:

Note: Not covered by the Emissions Control Systems Warranty:

•Malfunctions caused by misuse, improper adjustments, modification, alteration, tampering, disconnection, improper or inadequate maintenance and use of improper diesel fuel or DEF.

•Damage resulting from accident, acts of nature or other events beyond the control of Mack Trucks, Inc.

•

•

Inconvenience, loss of use of the vehicle, commercial loss of any kind including, but not limited to, consequential or incidental damages

Any vehicle in which the odometer has been altered or damaged so that mileage cannot be readily determined.

THISWARRANTYISEXPRESSLYINLIEUOFALLOTHERWARRANTIES AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Emissions Control System Warranty

The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal code of emission regulations.

1	Turbocharger Assembly			• CAC Hoses
	•	VGT Actuator	3	Engine Control Module (ECM)
2	Charge Air Cooler		4	Injectors
	•	CAC Pipes (Air inlet to/from CAC)

12 INTRODUCTION

5Engine and Vehicle Wire harness ( repair to circuits related to Emissions Warrantable Components )

6Exhaust Gas Recirculation (EGR) Mixer

7EGR Cooler

8EGR Valve and EGR Valve Control

9EGR Pipes - Engine Exhaust Manifold to EGR Cooler

10EGR Pipes - EGR Cooler to Inlet Manifold

11Crankcase Breather

12Crankcase Separator

13Crankcase Tubing and Hoses before Separator

14Aftertreatment Wiring Harness

15AftertreatmentControlModule(ACM)

16Aftertreatment Diesel Particulate Filter (DPF) Assembly

A. Aftertreatment DPF Assembly with Aftertreatment Diesel Oxidation Catalyst (DOC)

•Aftertreatment Doser

•Diffuser Pipe (Aftertreatment Fuel Doser Mounting)

•Fuel lines to Aftertreatment Fuel Doser

•Aftertreatment Fuel Shutoff Valve

•Aftertreatment Fuel Pressure Sensor

•Discharge Recirculation Valve (DRV) (Heat Mode)

•Discharge Recirculation Valve (DRV) Solenoid

•Engine Turbocharger Compressor Bypass Actuator (Heat Mode)

•Engine Turbocharger Compressor Bypass Actuator Solenoid

•Engine Exhaust Gas Temperature (EGT) Sensor

•Aftertreatment DPF Intake Temperature Sensor

•Aftertreatment DPF Outlet Temperature Sensor

•Aftertreatment DPF Differential Pressure Sensor

•Aftertreament Doser Air Supply Regulator (if applicable), Supply Lines, and Fittings

B. Thermal Regeneration Unit (TRU)

•Aftertreatment DPF Combustion Air Control Valve

•Aftertreatment DPF Combustion Air Valve

•Aftertreatment DPF Atomization Module

•Aftertreatment DPF Ignition Coil

•Aftertreatment DPF Fuel Control Valve

•Aftertreatment DPF Ignition Electrode

•Nozzle

•Engine Exhaust Gas Temperature (EGT) Sensor

•Aftertreatment DPF Intake Temperature Sensor

•Aftertreatment DPF Outlet Temperature Sensor

•Aftertreatment DPF Spark Assist Flame Temperature Sensor

•Aftertreatment DPF Differential Pressure Sensor

17Sensors:

•Crankshaft Position (CKP)

•Camshaft Position (CMP)

•Engine Coolant Temperature (ECT)

•Intake Manifold Air Temperature

•Intake Manifold Pressure (IMP)

•EGR Temperature

INTRODUCTION 13

•Aftertreatment Outlet NOx

•Aftertreatment Intake NOx

•EGR Differential Pressure

•Ambient Air Temperature (AAT) 18 SCR

•Aftertreatment Selective Catalytic Reduction (SCR) Catalyst

•Aftertreatment Diesel Exhaust Fluid (DEF) Pump

•Aftertreatment DEF Dosing Absolute Pressure Sensor

•Aftertreatment DEF Return Valve

•Aftertreatment DEF Dosing Valve

•Aftertreatment DEF Tank

•Aftertreatment DEF Tank Heater/Sender

•Aftertreatment DEF Tank Heater

•Aftertreatment DEF Tank Heater Valve

•Aftertreatment DEF Tank Temperature Sensor

•Aftertreatment DEF Level Sensor

•Aftertreatment DEF Heated Lines

19.Instrument Cluster (Repair of microprocessor , OBD MIL, Real Time Clock, Aftertreatment DEF Tank Gauge and, Aftertreatment DEF Tank Low Level Indicator)

20.Exhaust Gas Piping (from Turbocharger to Aftertreatment System )

21.Data Link Connector (DLC)

ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY

The emission warranty for the diesel particulate filter (DPF) and SCR System covers defects in workmanship only. Normal maintenance, such as cleaning ash from the filter at regular maintenance intervals and cleaning the aftertreatment fuel injector on Diesel oxidation catalyst (DOC) DPF systems, is not covered by the emission warranty. With the Thermal regenerator DPF system, cleaning the ignition electrodes and fuel injection nozzleattheregularmaintenanceintervals

is considered normal maintenance and not covered by the emission warranty.

Note: In response to customer requests, MackTrucks,Inc. maybuildvehicleswith engines supplied by other manufacturers. In these cases, each engine manufacturer through its service organization, is responsible for emission control systems warranty on all parts of the engine assembly, as furnished.

14 INTRODUCTION

FEDERAL EMISSION REQUIREMENTS

This section covers the requirement of the United States Clean Air Act which states: “The manufacturer shall furnish with each new motor vehicle or motor vehicle engine such written instructions for the maintenance and use of the vehicle or engine by the ultimate purchaser as may

be reasonable and necessary to assure the proper functioning of emission control devices and systems. ”This section also covers the requirements of the emissions regulations promulgated under the Motor Vehicle Safety Act in Canada.

TAMPERING WITH GASEOUS EMISSION CONTROL SYSTEMS PROHIBITED

The Federal Clean Air Act prohibits the removal or rendering inoperative of any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with Federal Emission Regulations by:

1Anypersonpriortoitssaleanddelivery to the ultimate purchaser, or

2Any manufacturer or distributor after its sale and delivery to the ultimate purchaser, or

3Any person engaged in the business of repairing, servicing, selling, leasing, or

tradingmotorvehiclesormotorvehicle engines following its sale and delivery to the ultimate purchaser, or

4Any person who operates a fleet of motor vehicles following its sale and delivery to the ultimate purchaser.

Note: For specifics of the prohibited vehicle/engine modifications refer to the Mack Trucks, Inc. Body Builders documentation .

EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA

The California Air Resources Board and Mack Trucks, Inc. are pleased to explain the California emission control system warranty on your new motor vehicle engine. In California, new motor vehicle engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Mack Trucks, Inc. must warrant the emission control system onyourenginefortheperiodoftimelisted below provided there has been no abuse, neglect, or improper maintenance of your engine.

Your emission control system may include parts such as the fuel-injection

system, turbocharger assembly, electronic control module and other emission-related assemblies.

Where a warrantable condition exists, Mack Trucks, Inc. will repair your engine at no cost to you including diagnosis, parts, and labor.

MANUFACTURER’S WARRANTY COVERAGE:

If an emission-related part of your engine is defective, the part will be repaired or replaced by Mack Trucks, Inc. This is your emission control system DEFECTS WARRANTY.

INTRODUCTION 15

OWNER’S WARRANTY RESPONSIBILITIES:

As the motor vehicle engine owner, you are responsible for the performance of the required maintenance listed in this manual. Mack Trucks, Inc. recommends that you retain all receipts covering maintenance of your vehicle, but Mack Trucks, Inc. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance listed in other manuals which were supplied with your vehicle.

You are responsible for presenting your motor vehicle engine to a MACK dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the motor vehicle engine owner, you should also be aware that Mack Trucks, Inc. may deny you warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

If you have any questions regarding your warranty rights and responsibilities, you should contact the Mack Trucks, Inc. Warranty Activities P.O.Box 26259, Greensboro, NC 27402, or the California Air Resources Board at 9480 Telstar Avenue, El Monte, California 91731.

(Applicable only to vehicles and/or engines certified for sale and registered

in the State of California) Mack Trucks, Inc. warrants the Emission Control Systems on each new MACK diesel engine in a new MACK truck to comply with all State of California emissions regulations applicable at the time of manufacture of the engine, and to be free from defects in material and workmanship under normal use and service up to

60 months, or 100,000 miles, or 3,000 engine operating hours, whichever occurs first, provided that all Mack Trucks, Inc. maintenance requirements are followed as described in this manual. All warranty periods are calculated from the date-in-service of the new vehicle. The repair or replacement of defective parts will be made without charge for the cost of parts and, if repairs are made at an authorized Mack Trucks, Inc. dealership, there will be no charge for labor.

Mack Trucks, Inc.’s obligation under this warranty is limited to the repair or replacement, at Mack Trucks, Inc.’s

option, of any part(s) of Emission Control Systems of such engine and/or vehicle foundtobedefectiveuponexaminationby Mack Trucks, Inc. and provided that such part(s) were returned to Mack Trucks, Inc. or its nearest authorized Dealer within a reasonable period of time.

Qualifications and Limitations:

Not covered by the Emissions Control Systems Warranty:

•Malfunctions caused by misuse, improper adjustments, modification, alteration, tampering, disconnection, improper or inadequate maintenance and use of improper diesel fuel or DEF.

•Damage resulting from accident, acts of nature or other events beyond the control of Mack Trucks, Inc.

•

•

Inconvenience, loss of use of the vehicle, commercial loss of any kind including, but not limited to, consequential or incidental damages.

Any vehicle in which the odometer has been altered or damaged so that mileage cannot be readily determined.

16 INTRODUCTION

THISWARRANTYISEXPRESSLYINLIEUOFALLOTHERWARRANTIES AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Emissions Control System Warranty

The following engine components are covered by the supplemental emissions control system warranty policy as required by the California code of regulations.

1Turbocharger Assembly

•VGT Actuator

2Charge Air Cooler

•CAC Pipes (Air inlet to/from CAC)

•CAC Hoses

3Engine Control Module (ECM)

4Injectors

5Engine and Vehicle Wire harness (repair to circuits related to Emissions Warrantable Components )

6Exhaust Gas Recirculation (EGR) Mixer

7EGR Cooler

8EGR Valve and EGR Valve Control

9EGR Pipes - Engine Exhaust Manifold to EGR Cooler

10EGR Pipes - EGR Cooler to Inlet Manifold

11Crankcase Breather

12Crankcase Separator

13Crankcase Tubing and Hoses before Separator

14Aftertreatment Wiring Harness

15AftertreatmentControlModule(ACM)

16Aftertreatment Diesel Particulate Filter (DPF) Assembly

A. Aftertreatment DPF Assembly with Aftertreatment Diesel Oxidation Catalyst (DOC)

•Aftertreatment Doser

•Diffuser Pipe (Aftertreatment Fuel Doser Mounting)

•Fuel lines to Aftertreatment Fuel Doser

•Aftertreatment Fuel Shutoff Valve

•Aftertreatment Fuel Pressure Sensor

•Engine Turbocharger Compressor Bypass Actuator (Heat Mode)

•Engine Turbocharger Compressor Bypass Actuator Solenoid

•Engine Exhaust Gas Temperature (EGT) Sensor

•Aftertreatment DPF Intake Temperature Sensor

•Aftertreatment DPF Outlet Temperature Sensor

•Aftertreatment DPF Differential Pressure Sensor

•Aftertreament Doser Air Supply Regulator (if applicable), Supply Lines, and Fittings

B. Thermal Regeneration Unit (TRU)

•Aftertreatment DPF Air Shutoff Valve

•Aftertreatment DPF Combustion Air Valve

•Aftertreatment DPF Atomization Module

•Aftertreatment DPF Ignition Coil

INTRODUCTION 17

•Aftertreatment DPF Fuel Control Valve

•Aftertreatment DPF Ignition Electrode

•Nozzle

•Engine Exhaust Gas Temperature (EGT) Sensor

•Aftertreatment DPF Intake Temperature Sensor

•Aftertreatment DPF Outlet Temperature Sensor

•Aftertreatment DPF Spark Assist Flame Temperature Sensor

•Aftertreatment DPF Differential Pressure Sensor

17Sensors:

•Crankshaft Position (CKP)

•Camshaft Position (CMP)

•Engine Coolant Temperature (ECT)

•Intake Manifold Air Temperature

•Intake Manifold Pressure (IMP)

•EGR Temperature

•Aftertreatment Outlet NOx

•Aftertreatment Intake NOx

•EGR Differential Pressure

•Ambient Air Temperature (AAT)

18SCR

•Aftertreatment Selective Catalytic Reduction (SCR) Catalyst

•Aftertreatment Diesel Exhaust Fluid (DEF) Pump

•Aftertreatment DEF Dosing Absolute Pressure Sensor

•Aftertreatment DEF Return Valve

•Aftertreatment DEF Dosing Valve

•Aftertreatment DEF Tank

•Aftertreatment DEF Tank Heater/Sender

•Aftertreatment DEF Tank Heater

•Aftertreatment DEF Tank Heater Valve

•Aftertreatment DEF Tank Temperature Sensor

•Aftertreatment DEF Level Sensor

•Aftertreatment DEF Heated Lines

19.Instrument Cluster (Repair of microprocessor , OBD MIL, Real Time Clock, Aftertreatment DEF Tank Gauge and, Aftertreatment DEF Tank Low Level Indicator)

20.Exhaust Gas Piping (from Turbocharger to Aftertreatment System )

21.Data Link Connector (DLC)

18 INTRODUCTION

ENGINE GASEOUS EMISSION CONTROL SYSTEMS

WARRANTY — Continued

The emission warranty for the diesel particulate filter (DPF) and SCR System covers defects in workmanship only. Normal maintenance, such as cleaning ash from the filter at regular maintenance intervals and cleaning the aftertreatment fuel injector on Diesel oxidation catalyst (DOC) DPF systems, is not covered by the emission warranty. With the Thermal regenerator DPF system, cleaning the ignition electrodes and fuel injection nozzleattheregularmaintenanceintervals is considered normal maintenance and not covered by the emission warranty.

Note: In response to customer requests, MackTrucks,Inc. maybuildvehicleswith engines supplied by other manufacturers. In these cases, each engine manufacturer through its service organization, is responsible for emission control systems warranty on all parts of the engine assembly, as furnished.

CAUTION

Any unauthorized adjustments to the emission control components can cause severe damage to the engine.

1.Repairs by MACK Dealers, Sub-Dealers and Service Dealers

Repairs covered by the California Emission Control Systems Warranty will be performed by any authorized MACK repair facility at his place of business with no charge for parts and labor (including diagnosis),usingMACKpartsforanypart of the emission control systems covered by this warranty and found defective.

2.In an Emergency

In an emergency, where an authorized MACK facility is not available, repairs may be performed at any available service

establishment, or by the owner, using any replacement part, within the limitations of paragraphs 3 and 4 in this section. An emergency condition exists under this section if, after 30 days, repairs have not been completed or parts are not yet available. MACK will reimburse the owner for such repairs that are covered under this warranty, including diagnosis, not to exceed MACK’s suggested retail price for parts replaced and labor charges based on MACK’s recommended time allowance and geographically appropriate hourly labor rate. Replaced parts and paid invoices must be presented at a MACK facilityasaconditionofreimbursementfor emergency repairs performed elsewhere.

CAUTION

In the event that damage results from unauthorized adjustments to any emission control system components, as evidenced by settings other than as specified, or broken fastener seals, the cost of repairing such damage WILL NOT BE COVERED under warranty

3.Repairs by Non-MACK Facilities

Owners may elect to have maintenance, replacement, or repair of emission control systems performed by any repair facility, and may elect to use parts other than MACK parts without invalidating the warranty on other components, but the cost of such service or parts will not be covered by MACK under its warranty.

4.Use of Non-MACK Parts

Useofreplacementpartswhicharenotthe equivalent of MACK parts may impair the effectiveness of emission control systems. If other than MACK parts are used, the

INTRODUCTION 19

owner should obtain assurances that such parts are warranted by their manufacturer to be the equivalent of MACK parts

in performance and durability. MACK assumes no liability under this warranty with respect to parts other than MACK parts; however, the use of non-MACK parts does not invalidate the warranty on othercomponentsunlessnon-MACKparts cause damage to warranted parts.

5.Maintenance and Maintenance Records

The vehicle owner is responsible for the performance of all required maintenance specified in this manual. MACK will not denyawarrantyclaimsolelybecausethere is no record of maintenance; however, MACK may deny a warranty claim if failure to perform required maintenance results in the failure of a warranted part. Receipts or other records covering the performance of scheduled maintenance should be retained to answer questions that may arise concerning maintenance. Maintenance records should be transferred tosubsequentownersifthevehicleissold.

6.Items Not Covered by the Emission Control Systems Warranty

•Malfunctions caused by misuse, improper adjustments, modification, alteration, tampering, disconnection, improper or inadequate maintenance and use of improper diesel fuel.

•Damage resulting from accident, acts of nature or other events beyond the control of Mack Trucks, Inc.

•Inconvenience, loss of use of the vehicle, commercial loss of any kind including, but not limited to, consequential or incidental damages.

•Any vehicle in which the odometer has been altered or damaged so that mileage cannot be readily determined.

7. Customer Assistance

MACKwishestoassurethattheCalifornia Emission Control Systems Warranty is properly administered. In the event that ownersdonotreceivethewarrantyservice to which they believe they are entitled under the California Emission Control Systems Warranty, they should contact the nearest MACK Regional Office for assistance. The address and telephone number for each Regional Office are

in the MACK Directory of Sales, Parts and Service Centers. Owners in need of additional assistance or information concerning the California Emission Control Systems Warranty may also contact:

Mack Trucks, Inc.

Warranty Activities

P.O. Box 26259

Greensboro, NC 27402