MACK MP7, MP8, MP10 Service Manual

Mack

WARRANTY
HANDBOOK

E M I S S I O N

CONTROL SYSTEMS

FOR MACK CLASS 8

DIESEL ENGINES

(MP7, MP8, and MP10)

EMISSION CONTROL SYSTEMS

WARRANTY HANDBOOK

®

WARRANTY
HANDBOOK

E M I S S I O N

CONTROL SYSTEMS

FOR MACK CLASS 8

DIESEL ENGINES

(MP7, MP8, and MP10)

21394656

© Mack Trucks, Inc. 2010
Printed in U.S.A.

21394656

21394656

April 2010

Contents

EmissionControlSystems.........................................................................1

EmissionControlSystems........................................................................1

WarningLabelInformation.......................................................................2

VEHICLEDAT A...................................................................................4

EMISSIONSCONTROLCOMPLIANCE....................................................9

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS................................12

EmissionsControlSystemWarranty...........................................................13

CaliforniaEmissionControlSystemsWarranty..............................................17

EmissionControlSystems1

EmissionControlSystems

DONOTRemovethismanualfromthevehicle.Itcontainsimportantoperational
andsafetyinformationthatisneededbyalldriversandownersofthisvehicle.

ThishandbookaccompanieseachnewMACKvehicle.Itspurposeistoprovidethe
operatorwithareadyreferenceforvariousUnitedStatesFederal,CanadaFederal,and
CaliforniaStateregulationswhichgovernengineemissions.ItalsoprovidesW arranty
informationfortheMACKenginesandtheaccompanyingemissionssystems.

InformationinthishandbookhasbeenapprovedbytheU.S.EnvironmentalProtection
AgencyandtheCaliforniaAirResourcesBoardforthecurrentmodelyear,butis
subjecttotheeffectofchangesinapplicableregulationsandvehiclecontent.

ThismanualcoversMACKdieselenginesonly.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)andMACKTRUCKS
INC.shouldbeinformedimmediatelyifyoubelievethatthevehiclehasadefect
thatcouldcauseacrash,injuryordeath.

ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)327-4236,bywritingto
NHTSA,U.S.DepartmentofTransportation,Washington,DC20590,byTTYat1
[phone],orvisittheirwebsiteatwww.nhtsa.dot.gov.

MACKTRUCKSINC.,adivisionofVOL VOGroupNorthAmerica,LLC

Greensboro,NCUSA

Ordernumber:PV776-21394656

2010MACKTRUCKSINC.,Greensboro,NCUSA

Allrightsreserved.Nopartofthispublicationmaybereproduced,storedin
retrievalsystem,ortransmittedinanyformsbyanymeans,electronic,mechanical,
photocopying,recordingorotherwise,withoutthepriorwrittenpermissionofMACK
TRUCKSINC.

2EmissionControlSystems

WarningLabelInformation

IMPORTANT:Beforedrivingthisvehicle,becertainthatyouhavereadandthat
youfullyunderstandeachandeverystepofthedrivingandhandlinginformation
inthisOperatorsManual.Becertainthatyoufullyunderstandandfollowall
safetywarnings.Itisextremelyimportantthatthisinformationisreadand
understoodbeforethevehicleisoperated.

ITISIMPORTANTTHA TTHEFOLLOWINGINFORMATIONCONCERNING
LABELSBEREAD,UNDERSTOODANDALW AYSFOLLOWED.

Thefollowingtypesoflabelsareusedthroughoutthismanual:

Note:Anotedenesanoperatingprocedure,practice,condition,etc.,whichis
essentialtoproperoperationofthevehicle.

DANGER

Adangerlabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresult
inseriouspersonalinjuryordeath.Thedangerlabelisinwhitetypeonablack
backgroundwithablackborder.

WARNING

Awarninglabeldirectstheoperatorsattentiontounsafepracticeswhichcould
resultinpersonalinjuryorseveredamagetothevehicle.Thewarninglabelisin

blacktypeonagraybackgroundwithablackborder.

CAUTION

Acautionlabeldirectstheoperatorsattentiontounsafepracticeswherepersonal
injuryisnotlikelybutpropertydamagecouldoccur.Thecautionlabelisinblack
typeonawhitebackgroundwithablackborder.

CALIFORNIAPROPOSITION65WARNING

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCalifornia
tocausecancer,birthdefectsandotherreproductiveharm.

EmissionControlSystems3

CALIFORNIAPROPOSITION65WARNING

Batteryposts,terminalsandotherrelatedaccessoriescontainleadandlead
compounds,chemicalknowntotheStateofCaliforniatocausecancerandother
reproductiveharm.
BatteriesalsocontainotherchemicalsknowntotheStateofCaliforniatocausecancer.

Washhandsafterhandling.

WarningandAdvisoryLabels

Advisory,Danger,WarningandCautionlabelsareplacedinvariouslocationsof
thevehicletoalertdriversandservicetechniciansaboutsituationsthatmaylead
topersonalinjuryorequipmentdamage.Intheeventthatalabelisdamagedor
missingthelabelmustbereplaced.ContactyourauthorizedMACKTruckdealer
forassistanceregardingWarningandAdvisorylabels.

4EmissionControlSystems

VEHICLEDA TA

Locatethefollowingserialnumbersandwritethemintheboxesprovided
nexttoeachillustration.

VINLocations

TheV ehicleIdenticationNumber(VIN)isdisplayedintwolocations(aframerail
stampingandalabel).The17-digitVINmustbeidenticalinbothlocations.

TheVINframestampingislocatedonthebottomrightframerailangeandthetop
leftrailange.NotethattheVINlocationmayvaryifre-stampingoftheframe
becomesnecessary.

C0028939

C0028940

TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.

C0028941

EmissionControlSystems5

EngineIdentication

OntheMACKMPengines,theengineserialnumberisstampedontheleft
sideoftheengineblock,belowtheinletmanifold.

C0028943

6EmissionControlSystems

EngineInformationPlate

IncompliancewithFederalemissionrequirements,anengineinformationlabelis
afxedtoallMACKdieselengines.Thislabel,whichislocatedonthecylinderhead
coveratthefrontoftheengine,givesbasicengineidenticationinformation(engine
model,serialnumber,etc.),advertisedhorsepoweratratespeed,inletandexhaust
valvelashsetting.TheEnginefamily“A VPTH12.8S01”canbeusedtoidentifythe
emissionstandardunderwhichtheenginewascertied.

W2040455

EngineIdenticationLabel—49StateEP AApprovedEnginewithoutCalifornia“CleanIdle”

W2040456

EngineIdenticationLabel—50StateEP AApprovedEnginewithCalifornia“CleanIdle”

EmissionControlSystems7

CAUTION

Tomaintaincompliancewithemission
regulations,enginesettingsshouldnot
bechangedfromthosespeciedonthe
engineinformationlabel.

Note:BoththeU.S.EPAandCaliforniaAirResourcesBoardrequiresthateach
enginebeidentiedwiththeproperenginelabelasshownabove.Shouldthisengine
labelbedefaced,destroyed,orremovedfromthevalvecover,itmustbereplaced
immediately.Toorderareplacementlabel,pleasecontactSpecicationsorParts
Interpretationsdepartmentat1–800–888–9878,Option2,whowillassistyouin
obtainingthecorrectlabelforyourengine.

8EmissionControlSystems

CleanIdleEngines

TheCaliforniaAirResourcesBoard(CARB)requiresthatanyengineshaving
tamper-resistantsoftwarewhichlimitsthetimeatwhichtheenginecanidleatspeeds
abovelowidle(550–700rpm).Atspeedsabovelowidle,andwithoutaPTO
engaged,idletimewillbelimitedtoveminutes,afterwhichtheenginewillrevert
backtolowidle.V ehiclesequippedwithaCleanIdleengineareidentiedbyalabel
whichisafxedtotheleftfrontcornerofthehoodoronthedriver’sdoorbelowthe
window,oronaverticaloutwardfacingcaborsleeperpanelextendingrearward
fromthelowerdoorposition.

CleanIdleEngineLabel

W2056289

EmissionControlSystems9

EMISSIONSCONTROLCOMPLIANCE

ExhaustEmissions

General

USA

TheFederalCleanAirAct,Section203(a)(3),statesthefollowingconcerningthe
removalofairpollutioncontroldevicesormodicationofacertiedenginetoa
non-certiedconguration:
CAA,Section(a)(3)(A)prohibitsanypersonfromremovingorrenderinginoperative
anyemissioncontroldeviceorelementofdesigninstalledonorinamotorvehicle
ormotorvehicleengineincompliancewithfederalregulationsundertheCleanAir
Actpriortothesaleanddeliveryofthevehicletotheultimatepurchaser .Thestatute
alsoprohibitsanypersonfromknowinglyremovingorrenderinginoperativeany
emissioncontroldeviceorelementofdesignaftersaleanddeliveryofavehicleor
enginetotheultimatepurchaser.Anypersonwhoviolatestheseprovisionseitherby
removingorrenderinginoperativeemissionscontroldevicespriortothesaleand
deliveryofanengineorvehicletoanultimatepurchaser,orbyknowinglyremoving
orrendinginoperativesuchdevicesafterthesaleanddeliveryofanengineorvehicle
toanultimatepurchaser,canbesubjecttopenaltiesofupto$3,750perincident.
Anydealerormanufacturerwhoviolatestheseprovisionscanbesubjecttopenalties
ofupto$37,500perincident.

Canada

ThesameconditionsthatapplyintheUSAapplytoCanada,withoneexception.
Afterthevehicleissoldtoaretailcustomer,thatis,theenduser,thejurisdiction
controllingtheemissioncontroldevicesbecomestheprovinceinwhichthevehicleis
licensed.Nochangesshouldbemadethatrenderanyorallofthedevicesinoperative.
Iftheowner/operatorwishestomakechangestotheemissioncontroldevices,check
withtheprovincialauthoritybeforechangesaremade.

Mexico

ThesameconditionsthatapplyintheUSAapplytoMexico.RefertotheMexican
FederalLawforEmissionControlwhichadherestoEP Aregulations.Nochanges
shouldbemadethatrenderanyoralloftheemissionscontroldevicesinoperative.
Iftheowner/operatorwishestomakechangestotheemissioncontroldevices,check
withthestateauthoritybeforechangesaremade.

10EmissionControlSystems

B5ApprovalForMACKUS2010CertiedProducts

MACKenginesarecertiedtocomplywithU.S.EP AandCaliforniaemissions
standardsbasedupontheuseoftestfuelswithspecicationsestablishedbythese
regulatoryagencies.Alternativefuels,includingbiodiesel,thatarenotsubstantially
similartotherequiredtestfuelsmayadverselyaffectengineemissionscompliance
andmayimpacttheperformanceofcertainemissionsaftertreatmentcomponents.As
aresult,MACKdoesnotwarranttheenginewillconformtoapplicableFederalor
Californiaemissionslimitswhenoperatedon,orhavingoperatedon,biodieselor
otheralternativefuelsthatarenotsubstantiallysimilartospeciedtestfuelsusedfor
certication.
Theuseofbiodieseluptoamaximumof5%(B5)inandofitself,willnotaffect
themanufacturer’smechanicalwarrantyastoengineandemissionssystemrelated
componentsexceptaslimitedbelowwithrespecttoaftertreatmentcomponents,
providedthebiofuelusedintheblendconformstoASTMD6751andB1toB5
blendsconformtoASTMD975.
Failuresofcertainemissionsaftertreatmentcomponents,specicallySCR,DPF
andNOxsensorswillnotbewarrantediffailurecanbeattributedtooperationon
biodieselblendsfrom6to20%(B6toB20)evenifbiofuelusedintheblendB6to
B20conformstoASTMD7467oranyrelatedstandard.

CAUTION

Diesel-poweredenginesforheavy-dutytrucksbuiltonorafterJanuary1,2007are
designedtooperateonlywithUltraLowSulfurDiesel(ULSD)fuel.Improper
fuelusewillreducetheefciencyanddurabilityofengines,permanentlydamage
advancedemissionscontrolsystems,reducefueleconomyandpossiblypreventthe
vehiclesfromrunningatall.Manufacturerwarrantieswillbevoidedbyimproper
fueluse.Additionally,burningLowSulfurDieselfuel(insteadofULSDfuel)in
2007andlatermodelyeardiesel-poweredcars,trucksandbusesisillegaland
punishablewithcivilpenalties.

CAUTION

UltraLowSulfurDiesel(ULSD)fuelwithamaximumsulfurcontentof15ppm
mustbeusedinordertomeetEuro4engineemissionrequirements.Using
otherwiseapproveddieselfuelswithamaximumsulfurcontentgreaterthan500
ppmmayshortenenginelifeandvoidtheenginewarranty.

EmissionControlSystems11

Airisalwayspresentinsidethefueltanks,enteringmainlythroughthetank
ventilation.Withtheairbeingheatedandcooled,condensationisformedandwater
ismixedinthefuel.Toavoidcondensationwhenthevehicleisparkedforlonger
periods,llthetanksupto95%ofcapacity .Donotllmorethanthat,asthefuel
needstohaveroomforexpansionduringtheheatoftheday.
Foradditionalinformationaboutfuel,refertotheOperator’sManualV ehicle
Maintenance.

AnindicatorwillappearintheDIDscreenwhenthereisapproximately3.875liters
(0.9gallons)remaininginthereservoir.

Note:Thisindicatorisoptional.Itcanbedeleted.

DANGER

DONOTcarryextrafuelcontainersin
thecab.Fuelcontainers,fullorempty,
mayleak,explodeorgiveaddedfuelto
are.Failuretofollowthisprecaution
mayleadtoseriouspersonalinjuryor
death.

DANGER

DONOTsmokewhilefueling
thevehicle.Theglowfromthe
cigar/cigarettecanignitethediesel
fuel,causinganexplosionresultingin
seriouspersonalinjuryordeath.

DANGER

Donotremovethefueltankcapnear
anopename.Dieselfuelvaporsare
combustibleandcancauseanexplosion
orre,resultinginseverepersonal
injuryordeath.

12EmissionControlSystems

ENGINEGASEOUSEMISSIONCONTROL
SYSTEMS

WARRANTYMAINTENANCE

Note:ForemissioncontrolsystemsinformationonenginesotherthanMACK,refer
totheenginevendor’spublication

GASEOUSEMISSIONCONTROLSYSTEMSWARRANTY

Note:ForemissioncontrolsystemsinformationonenginesotherthanMACK,refer
totheenginevendorspublications.

MACKTRUCKSINC.warrantstheEmissionControlSystemsoneachnewMACK
dieselengineinanewMACKtrucktocomplywithallUnitedStatesFederaland
Canadianemissionsregulationsapplicableatthetimeofmanufactureoftheengine,
andtobefreefromdefectsinmaterialandworkmanshipundernormaluseandservice
upto60months,or161000km(100,000mi),whicheveroccursrst.Allwarranty
periodsarecalculatedfromthedata-in-serviceofthenewvehicle.Therepairor
replacementofdefectivepartswillbemadewithoutchargeforthecostofpartsand,
ifrepairsaremadeatanauthorizedMACKTRUCKSINC.dealership,therewill
benochargeforlabor.

MACKTRUCKSINC.sobligationunderthiswarrantyislimitedtotherepairor
replacement,atMACKTRUCKSINC.soption,ofanypart(s)oftheEmissionControl
Systemsofsuchengineand/orvehiclefoundtobedefectiveuponexaminationby
MACKTRUCKSINC.andprovidedthatsuchpart(s)werereturnedtoMACK
TRUCKSINC.oritsnearestauthorizedDealerwithinareasonableperiodoftime.

QualicationsandLimitations:

N

otcoveredbytheEmissionsControlSystemsWarranty:

•Malfunctionscausedbymisuse,improperadjustments,modication,alteration,

tampering,disconnection,improperorinadequatemaintenanceanduseof
improperdieselfuel.

•Damageresultingfromaccident,actsofnatureorothereventsbeyondthecontrol

ofMACKTRUCKSINC.

•Inconvenience,lossofuseofthevehicle,commerciallossofanykindincluding,

butnotlimitedto,consequential,incidentaldamages.

•Anyvehicleinwhichtheodometerhasbeenalteredordamagedsothatmileage

cannotbereadilydetermined.

THISW ARRANTYISEXPRESSLYINLIEUOFALLOTHERWARRANTIES
ANDREPRESENTA TIONSORCONDITIONS,STA TUTORYOR
OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED
TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA
PARTICULARPURPOSE.

EmissionControlSystems13

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandV ehicleWireharness(repairtocircuitsrelatedtoEmissions

WarrantableComponents)

6ExhaustGasRecirculation(EGR)Mixer

7EGRCooler

8EGRV alveandEGRV alveControl

9EGRPipes-EngineExhaustManifoldtoEGRCooler

10EGRPipes-EGRCoolertoInletManifold

11CrankcaseBreather

12CrankcaseSeparator

13CrankcaseTubingandHosesbeforeSeparator

14AftertreatmentWiringHarness

15AftertreatmentControlModule(ACM)

16AftertreatmentDieselParticulateFilter(DPF)Assembly

A.AftertreatmentDPFAssemblywithAftertreatmentDieselOxidationCatalyst
(DOC)

•AftertreatmentDoser

•DiffuserPipe(AftertreatmentFuelDoserMounting)

•FuellinestoAftertreatmentFuelDoser

•AftertreatmentFuelDoserAirSupplyRegulator(ifapplicable,supplylines

andttings)

•AftertreatmentFuelShutoffV alve

•AftertreatmentFuelPressureSensor

•EngineTurbochargerCompressorBypassActuator(HeatMode)

•EngineTurbochargerCompressorBypassActuatorSolenoid

•EngineExhaustGasT emperature(EGT)Sensor

•AftertreatmentDPFIntakeT emperatureSensor

•AftertreatmentDPFOutletT emperatureSensor

14EmissionControlSystems

•AftertreatmentDPFDifferentialPressureSensor

B.AftertreatmentDPFSparkAssistedAssembly

•AftertreatmentDPFCombustionAirControlV alve

•AftertreatmentDPFAtomizationModule

•AftertreatmentDPFIgnitionCoil

•AftertreatmentDPFFuelControlV alve

•AftertreatmentDPFIgnitionElectrode

•Nozzle

•EngineExhaustGasT emperature(EGT)Sensor

•AftertreatmentDPFIntakeT emperatureSensor

•AftertreatmentDPFOutletT emperatureSensor

•AftertreatmentDPFSparkAssistFlameT emperatureSensor

•AftertreatmentDPFDifferentialPressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirT emperature(AA T)

18SCR

•AftertreatmentSelectiveCatalyticReduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid(DEF)Pump

•AftertreatmentDEFDosingAbsolutePressureSensor

•AftertreatmentDEFReturnV alve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFT ank

•AftertreatmentDEFTankHeaterV alve

•AftertreatmentDEFTankHeater/Sender

•AftertreatmentDEFT ankHeater

•AftertreatmentDEFTankT emperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

EmissionControlSystems15

19InstrumentCluster(Repairofmicroprocessor,OBDMIL,RealTimeClock,

AftertreatmentDEFT ankGaugeand,AftertreatmentDEFTankLowLevel
Indicator)ExhaustGasPiping(fromTurbochargertoAftertreatmentSystem)

20ExhaustGasPiping(fromTurbochargertoAftertreatmentSystem)

21DataLinkConnector(DLC)

ENGINEGASEOUSEMISSIONSCONTROL
SYSTEMWARRANTY

TheemissionwarrantyforthedieselparticulatelterandSCRSystemcovers
defectsinworkmanshiponly.Normalmaintenance,suchascleaningashfromthe
lteratregularmaintenanceintervalsandcleaningtheaftertreatmentfuelinjector
onDieselOxidationCatalyst(DOC)DPFsystems,isnotcoveredbytheemission
warranty.WiththeThermalregeneratorDPFsystem,cleaningtheignitionelectrodes
andfuelinjectionnozzleattheregularmaintenanceintervalsisconsiderednormal
maintenanceandnotcoveredbytheemissionwarranty.

Note:Inresponsetocustomerrequests,MackTrucks,Inc.maybuildvehicleswith
enginessuppliedbyothermanufacturers.Inthesecases,eachenginemanufacturer
throughitsserviceorganization,isresponsibleforemissioncontrolsystemswarranty
onallpartsoftheengineassembly,asfurnished.

16EmissionControlSystems

FEDERALEMISSIONREQUIREMENTS

ThissectioncoverstherequirementoftheUnitedStatesCleanAirActwhichstates:
“Themanufacturershallfurnishwitheachnewmotorvehicleormotorvehicleengine
suchwritteninstructionsforthemaintenanceanduseofthevehicleorengineby
theultimatepurchaserasmaybereasonableandnecessarytoassuretheproper
functioningofemissioncontroldevicesandsystems.”Thissectionalsocoversthe
requirementsoftheemissionsregulationspromulgatedundertheMotorVehicle
SafetyActinCanada.

TAMPERINGWITHGASEOUSEMISSIONCONTROLSYSTEMS
PROHIBITED

TheFederalCleanAirActprohibitstheremovalorrenderinginoperativeofany
deviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengine
incompliancewithFederalEmissionRegulationsby:

1Anypersonpriortoitssaleanddeliverytotheultimatepurchaser,or

2Anymanufacturerordistributorafteritssaleanddeliverytotheultimatepurchaser,

or

3Anypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or

tradingmotorvehiclesormotorvehicleenginesfollowingitssaleanddelivery
totheultimatepurchaser,or

4Anypersonwhooperatesaeetofmotorvehiclesfollowingitssaleanddelivery

totheultimatepurchaser.

Note:Forspecicsoftheprohibitedvehicle/enginemodicationsrefertotheMACK
Bodybuilderdocumentation.

EmissionControlSystems17

CaliforniaEmissionControlSystemsWarranty

Note:W arrantycoverageissubjecttochangewithoutnotice.ContactyourMACK
truckdealerforthecurrentwarrantystatement.

TheCaliforniaAirResourcesBoardandMACKTRUCKSINC.arepleasedto
explaintheCaliforniaemissioncontrolsystemwarrantyonyournewmotorvehicle

engine.InCalifornia,newmotorvehicleenginesmustbedesigned,builtandequipped
tomeettheStatesstringentanti-smogstandards.MACKTRUCKSINC.mustwarrant
theemissioncontrolsystemonyourenginefortheperiodoftimelistedbelow
providedtherehasbeennoabuse,neglect,orimpropermaintenanceofyourengine.

Youremissioncontrolsystemmayincludepartssuchasthefuel-injectionsystem,
turbochargerassembly,electroniccontrolmoduleandotheremission-related
assemblies.

Whereawarrantableconditionexists,MACKTRUCKSINC.willrepairyourengine
atnocosttoyouincludingdiagnosis,parts,andlabor.

Manufacturer’sWarrantyCoverage:

Ifanemission-relatedpartofyourengineisdefective,thepartwillberepairedor
replacedbyMACKTRUCKSINC.ThisisyouremissioncontrolsystemDEFECTS
WARRANTY .

18EmissionControlSystems

Owner’sWarrantyResponsibilities:

Asthemotorvehicleengineowner,youareresponsiblefortheperformanceofthe
requiredmaintenancelistedinthismanual.MACKTRUCKSINC.recommendsthat
youretainallreceiptscoveringmaintenanceofyourvehicle,butMACKTRUCKS
INC.cannotdenywarrantysolelyforthelackofreceiptsorforyourfailuretoensure
theperformanceofallscheduledmaintenancelistedinothermanualswhichwere
suppliedwithyourvehicle.

YouareresponsibleforpresentingyourmotorvehicleenginetoaMACKdealeras
soonasaproblemexists.Thewarrantyrepairsshouldbecompletedinareasonable
amountoftime,nottoexceed30days.

Asthemotorvehicleengineowner,youshouldalsobeawarethatMACKTRUCKS
INC.maydenyyouwarrantycoverageifyourvehicleoraparthasfaileddueto
abuse,neglect,impropermaintenance,orunapprovedmodications.

Ifyouhaveanyquestionsregardingyourwarrantyrightsandresponsibilities,you
shouldcontacttheMACKTRUCKSINC.WarrantyDepartmentatP .O.Box26115,
Greensboro,NC27402-6115,ortheCaliforniaAirResourcesBoardat9480T elstar
Avenue,ElMonte,California91731.

(Applicableonlytovehiclesand/orenginescertiedforsaleandregisteredin
theStateofCalifornia)

MACKTRUCKSINC.warrantstheEmissionControlSystemsoneachnewMACK
dieselengineinanewMACKtrucktocomplywithallStateofCaliforniaemissions
regulationsapplicableatthetimeofmanufactureoftheengine,andtobefreefrom
defectsinmaterialandworkmanshipundernormaluseandserviceupto60months,
or161000km(100,000m),or3,000engineoperatinghours,whicheveroccursrst.
Allwarrantyperiodsarecalculatedfromthedate-in-serviceofthenewvehicle.The
repairorreplacementofdefectivepartswillbemadewithoutchargeforthecostof
partsand,ifrepairsaremadeatanauthorizedMACKTRUCKSINC.dealership,
therewillbenochargeforlabor.

MACKTRUCKSINC.obligationunderthiswarrantyislimitedtotherepairor
replacement,atMACKTRUCKSINC.option,ofanypart(s)oftheEmissionControl
Systemsofsuchengineand/orvehiclefoundtobedefectiveuponexaminationby
MACKTRUCKSINC.andprovidedthatsuchpart(s)werereturnedtoMACK
TRUCKSINC.oritsnearestauthorizedDealerwithinareasonableperiodoftime.

EmissionControlSystems19

QualicationsandLimitations:

NotcoveredbytheEmissionsControlSystemsWarranty:

•Malfunctionscausedbymisuse,improperadjustments,modication,alteration,

tampering,disconnection,improperorinadequatemaintenanceanduseof
improperdieselfuel.

•Damageresultingfromaccident,actsofnatureorothereventsbeyondthecontrol

ofMACKTRUCKSINC.

•Inconvenience,lossofuseofthevehicle,commerciallossofanykindincluding,

butnotlimitedto,consequential,incidentaldamages.

•Anyvehicleinwhichtheodometerhasbeenalteredordamagedsothatmileage

cannotbereadilydetermined.

THISW ARRANTYISEXPRESSLYINLIEUOFALLOTHERWARRANTIES
ANDREPRESENTA TIONSORCONDITIONS,STA TUTORYOR
OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED
TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA
PARTICULARPURPOSE.

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheCaliforniaCodeofRegulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandV ehicleWireharness(repairtocircuitsrelatedtoEmissions

WarrantableComponents)

6ExhaustGasRecirculation(EGR)Mixer

7EGRCooler

8EGRV alveandEGRV alveControl

9EGRPipes-EngineExhaustManifoldtoEGRCooler

10EGRPipes-EGRCoolertoInletManifold

11CrankcaseBreather

12CrankcaseSeparator

20EmissionControlSystems

13CrankcaseTubingandHosesbeforeSeparator

14AftertreatmentWiringHarness

15AftertreatmentControlModule(ACM)

16AftertreatmentDieselParticulateFilter(DPF)Assembly

A.AftertreatmentDPFAssemblywithAftertreatmentDieselOxidationCatalyst
(DOC)

•AftertreatmentDoser

•DiffuserPipe(AftertreatmentFuelDoserMounting)

•FuellinestoAftertreatmentFuelDoser

•AftertreatmentFuelDoserAirSupplyRegulator(ifapplicable,supplylines

andttings)

•AftertreatmentFuelShutoffV alve

•AftertreatmentFuelPressureSensor

•EngineTurbochargerCompressorBypassActuator(HeatMode)

•EngineTurbochargerCompressorBypassActuatorSolenoid

•EngineExhaustGasT emperature(EGT)Sensor

•AftertreatmentDPFIntakeT emperatureSensor

•AftertreatmentDPFOutletT emperatureSensor

•AftertreatmentDPFDifferentialPressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirT emperature(AA T)

B.AftertreatmentDPFSparkAssistedAssembly

•AftertreatmentDPFCombustionAirControlV alve

•AftertreatmentDPFCombustionAirV alve

•AftertreatmentDPFAtomizationModule

•AftertreatmentDPFIgnitionCoil

•AftertreatmentDPFFuelControlV alve

•AftertreatmentDPFIgnitionElectrode

EmissionControlSystems21

•Nozzle

•EngineExhaustGasT emperature(EGT)Sensor

•AftertreatmentDPFIntakeT emperatureSensor

•AftertreatmentDPFOutletT emperatureSensor

•AftertreatmentDPFSparkAssistFlameT emperatureSensor

•AftertreatmentDPFDifferentialPressureSensor

18SCR

•AftertreatmentSelectiveCatalyticReduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid(DEF)Pump

•AftertreatmentDEFDosingAbsolutePressureSensor

•AftertreatmentDEFReturnV alve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFT ank

•AftertreatmentDEFTankHeaterV alve

•AftertreatmentDEFTankHeater/Sender

•AftertreatmentDEFT ankHeater

•AftertreatmentDEFTankT emperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

19InstrumentCluster(Repairofmicroprocessor,OBDMIL,RealTimeClock,

AftertreatmentDEFT ankGaugeand,AftertreatmentDEFTankLowLevel
Indicator)ExhaustGasPiping(fromTurbochargertoAftertreatmentSystem)

20ExhaustGasPiping(fromTurbochargertoAftertreatmentSystem)

21DataLinkConnector(DLC)

22EmissionControlSystems

CAUTION

Anyunauthorizedadjustmentstotheemissioncontrolcomponentscancause
severedamagetotheengine.

TheemissionwarrantyforthedieselparticulatelterandSCRSystemscoversdefects
inworkmanshiponly.Normalmaintenance,suchascleaningashfromthelterat
regularmaintenanceintervalsandcleaningtheAftertreatmentfuelinjectoronDiesel
OxidationCatalyst(DOC)DPFsystems,isnotcoveredbytheemissionwarranty.
WiththeThermalRegenerationDPFsystem,cleaningtheignitionelectrodesand
fuelinjectionnozzleattheregularmaintenanceintervalsisconsiderednormal
maintenanceandnotcoveredbytheemissionwarranty.

Note:Inresponsetocustomerrequests,MACKTRUCKSINC.maybuild
vehicleswithenginessuppliedbyothermanufacturers.Inthesecases,eachengine
manufacturerthroughitsserviceorganization,isresponsibleforemissioncontrol
systemswarrantyonallpartsoftheengineassembly,asfurnished.

1RepairsbyMACKdealers,Sub-DealersandServiceDealers

RepairscoveredbytheCaliforniaEmissionControlSystemsWarrantywillbe
performedbyanyauthorizedMACKrepairfacilityathisplaceofbusinesswithno
chargeforpartsandlabor(includingdiagnosis),usingMACKpartsforanypartof
theemissioncontrolsystemscoveredbythiswarrantyandfounddefective.

2InanEmergency

Inanemergency,whereanauthorizedMACKfacilityisnotavailable,repairs
maybeperformedatanyavailableserviceestablishment,orbytheowner,using
anyreplacementpart,withinthelimitationsofparagraphs4and5inthissection.
Anemergencyconditionexistsunderthissectionif,after30days,repairshavenot
beencompletedorpartsarenotyetavailable.MACKwillreimbursetheowner
forsuchrepairsthatarecoveredunderthiswarranty,includingdiagnosis,notto
exceedMACKssuggestedretailpriceforpartsreplacedandlaborchargesbased
onMACKsrecommendedtimeallowanceandgeographicallyappropriatehourly
laborrate.ReplacedpartsandpaidinvoicesmustbepresentedataMACKfacility
asaconditionofreimbursementforemergencyrepairsperformedelsewhere.

CAUTION

Intheeventthatdamageresultsfromunauthorizedadjustmentstoanyemission
controlsystemcomponents,asevidencedbysettingsotherthanasspecied,
orbrokenfastenerseals,thecostofrepairingsuchdamageWILLNOTBE
COVEREDunderwarranty.

EmissionControlSystems23

3RepairsbyNon-MACKFacilities

Ownersmayelecttohavemaintenance,replacement,orrepairofemissioncontrol
systemsperformedbyanyrepairfacility,andmayelecttousepartsotherthan
MACKpartswithoutinvalidatingthewarrantyonothercomponents,butthecost
ofsuchserviceorpartswillnotbecoveredbyMACKunderitswarranty .

4UseofNon-MACKParts

UseofreplacementpartswhicharenottheequivalentofMACKpartsmayimpair
theeffectivenessofemissioncontrolsystems.IfotherthanMACKpartsare
used,theownershouldobtainassurancesthatsuchpartsarewarrantedbytheir
manufacturertobetheequivalentofMACKpartsinperformanceanddurability.
MACKassumesnoliabilityunderthiswarrantywithrespecttopartsotherthan
MACKparts;however,theuseofnon-MACKpartsdoesnotinvalidatethe
warrantyonothercomponentsunlessnon-MACKpartscausedamagetowarranted
parts.

5MaintenanceandMaintenanceRecords

Thevehicleownerisresponsiblefortheperformanceofallrequiredmaintenance.
MACKwillnotdenyawarrantyclaimsolelybecausethereisnorecordof
maintenance;however,MACKmaydenyawarrantyclaimiffailuretoperform
requiredmaintenanceresultsinthefailureofawarrantedpart.Receiptsorother
recordscoveringtheperformanceofscheduledmaintenanceshouldberetainedto
answerquestionsthatmayariseconcerningmaintenance.Maintenancerecords
shouldbetransferredtosubsequentownersifthevehicleissold.

6ItemsNotCoveredbytheEmissionControlSystemsWarranty

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

Damageresultingfromaccident,actsofnatureorothereventsbeyondthecontrol
ofMACK.

Inconvenience,lossofuseofthevehicle,orcommercialloss.

Anyvehicleonwhichtheodometerhasbeenchangedsothatmileagecannot
bereadilydetermined.

7CustomerAssistance

MACKTRUCKSINC.wishestoassurethattheCaliforniaEmissionControl
SystemsWarrantyisproperlyadministered.Intheeventthatownersdonotreceive
thewarrantyservicetowhichtheybelievetheyareentitledundertheCalifornia
EmissionControlSystemsW arranty,theyshouldcontactMACKTRUCKSINC.
WarrantyAdministration,[phone].Theaddressandtelephonenumber
ofeachRegionalOfceisinyourvehicleownerspackage.Ownersinneedof
additionalassistanceorinformationconcerningtheCaliforniaEmissionControl
SystemsWarrantymayalsocontact:
MACKTRUCKSINC.
WarrantyAdministration
[phone]