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Mack
®
MRU Series
Mack® TerraProTM Series
(MRU Series)
Mack® TerraProTM Series
(MRU Series)
21394655
21394655 21394655
© Mack Trucks, Inc. 2010
Printed in U.S.A.
April 2010
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Foreword
Thismanualcontainsinformationconcerningtheoperationand
functionoftheMackLinkSystem.Theinformationinthismanual
appliestovehiclesbuilt April2010andlater.Pleasekeepthismanual
inthevehicleatalltimes.
Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)and
MackTrucks,Inc.shouldbeinformedimmediatelyifyoubelievethat
thevehiclehasadefectthatcouldcauseacrash,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)
327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation,
Washington,DC20590,byTTYat1(800)424-9153,orvisittheir
websiteatwww.nhtsa.dot.gov.
Mack Trucks Inc.
Greensboro,NCUSA
Ordernumber:PV776-21394655
©2010 Mack TrucksInc.,Greensboro,NCUSA
Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionof Mack Trucks Inc.
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Contents
INTRODUCTION............................................................................................................1
TOTHEOWNER..........................................................................................................1
InAppreciation..........................................................................................................1
AboutThisHandbook................................................................................................2
THEVEHICLE..............................................................................................................3
BasicConguration...................................................................................................3
VehicleManagementandControlSystem(V-MAC®).............................................3
COMPONENTIDENTIFICATION..............................................................................4
VINLocations............................................................................................................4
EngineIdentication..................................................................................................5
EngineInformationPlate...........................................................................................6
CleanIdleEngines.....................................................................................................7
TransmissionIdentication........................................................................................8
WARRANTYINFORMA TION..................................................................................11
AirBrakeSystem.....................................................................................................11
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................11
EmissionsControlSystemWarranty.......................................................................12
ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............14
FEDERALEMISSIONREQUIREMENTS............................................................15
EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................15
EmissionsControlSystemWarranty.......................................................................17
SERVICELITERATURE............................................................................................21
–MACKClass8–ComponentsServiceManual....................................................21
–Class8–CustomCollatedServiceManualonCD..............................................21
CUSTOMERSERVICE..............................................................................................22
Call1-800-866-1177forMACKOneCall™...........................................................22
QuestionsandComplaints.......................................................................................22
Addresses.................................................................................................................23
AdditionalAssistance..............................................................................................23
REPORTINGSAFETYDEFECTS.............................................................................25
UnitedStates............................................................................................................25
Canada......................................................................................................................25
Mexico.....................................................................................................................25
EVENTDATARECORDINGDEVICES...................................................................26
SAFETYINFORMATION...........................................................................................27
SAFETYSTATEMENT..............................................................................................27
CERTIFICA TIONLABELS........................................................................................29
SafetyCerticationLabel........................................................................................29
ADVISORYLABELS.................................................................................................31
AdvisoryLabelLocations(OnV ehicle)..................................................................31
TRUCK-TRACTORCONSPICUITY.........................................................................39
CABENTRY/EXIT.....................................................................................................40
Three-LimbContact.................................................................................................40
DriverSide...............................................................................................................42
PassengerSide.........................................................................................................44
DeckPlateAccess....................................................................................................46
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SAFETYTIPSFORCOLDWEA THEROPERA TION.............................................48
DriverVisibility.......................................................................................................48
CabDoorSealsandKeyLocks...............................................................................49
OutsideMirrorHeater..............................................................................................49
AirHornSnowShield..............................................................................................50
EmergencyReectorKit..........................................................................................50
FireExtinguisher(Optional)....................................................................................50
INSTRUMENTSANDCONTROLS...........................................................................51
CABINTERIOR..........................................................................................................51
INSTRUMENTPANEL..............................................................................................52
Tell-T ales..................................................................................................................52
PanelArrangement...................................................................................................52
INSTRUMENTPANELGAUGELAYOUT..............................................................53
PanelA.....................................................................................................................53
PanelB.....................................................................................................................54
PanelC.....................................................................................................................55
PanelD.....................................................................................................................56
PanelE.....................................................................................................................57
Regeneration............................................................................................................63
ParkedRegeneration(IfNeeded).............................................................................65
DPFINHIBITROADSPEEDLIMITING(RSL)...................................................67
FunctionofOptionalSwitches.................................................................................71
CABCLIMATECONTROL.......................................................................................74
LIGHTCONTROLPANEL........................................................................................75
STEERINGCOLUMN................................................................................................76
ElectricalSwitch......................................................................................................76
FLOORPEDALS........................................................................................................77
MISCELLANEOUSCONTROLS..............................................................................78
DomeLight..............................................................................................................78
AirHorn...................................................................................................................79
FreshAirVent..........................................................................................................79
AccessoryPowerOutlets.........................................................................................79
PRE-TRIPINSPECTIONANDDAILYMAINTENANCE......................................81
PRE-TRIP....................................................................................................................81
Pre-TripInspectionQuickList................................................................................81
OPERATION..................................................................................................................94
.....................................................................................................................................94
NewVehicleBreak-In..............................................................................................94
WINDSHIELDWASHERRESERVOIR....................................................................96
CABTILTOPERA TION.............................................................................................97
TiltingtheCab.........................................................................................................98
LoweringtheCab...................................................................................................100
BleedingtheCabTiltSystem................................................................................101
HOSETENDERS......................................................................................................102
DOORS......................................................................................................................103
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StandardDoorPanel..............................................................................................103
OpeningtheCabDoor...........................................................................................104
LockingtheCabDoor............................................................................................104
REMOTEKEYLESSENTRY—(OPTIONAL)......................................................105
TransmitterOperations..........................................................................................106
BatteryReplacement..............................................................................................106
SEATBEL TS.............................................................................................................110
SeatBeltOperation................................................................................................110
FasteningSeatBelt................................................................................................110
Komfort®LatchSystem........................................................................................113
SEATADJUSTMENTANDRECLINE(IFEQUIPPED)........................................115
MACKENGINEINFORMATION...........................................................................115
PrecautionsandWarnings......................................................................................115
EngineModelDesignations...................................................................................117
CRUISECONTROLOPERATION..........................................................................118
SpeedControlSwitches.........................................................................................118
DisengagingCruiseControl...................................................................................119
MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................120
EngineBrakeSwitch..............................................................................................120
HowtheEngineBrakeisActivated.......................................................................121
CruiseControlwiththeMACKPowerLeash™EngineBrake.............................121
ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........123
OverFlatTerrain....................................................................................................123
DescendingaGrade...............................................................................................124
OnSlipperyRoadSurfaces....................................................................................126
BRAKEOPERATION...............................................................................................128
AirBrakeSystem...................................................................................................128
AutomaticSlackAdjusters....................................................................................129
ParkingBrakeSystem............................................................................................129
ParkingBrakeOperation........................................................................................130
Parking...................................................................................................................130
Anti-LockBrakeSystem(ABS)............................................................................130
AutomaticTractionControl(A TC)(IfEquipped).................................................134
GOODDRIVINGHABITS.......................................................................................136
WeightRatings.......................................................................................................136
Instruments.............................................................................................................136
ShuttingDowntheEngine.....................................................................................136
GeneralObservation..............................................................................................136
STARTINGTHEVEHICLE.....................................................................................137
GeneralInformation...............................................................................................137
PushButtonStarters...............................................................................................137
AirStarters.............................................................................................................138
EngineWarm-Up...................................................................................................140
EngineIdling..........................................................................................................141
ShuttingDowntheEngine.....................................................................................141
COLDWEATHEROPERA TION.............................................................................144
ColdWeatherStartingTips....................................................................................144
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EngineBlockHeaters............................................................................................145
Winterfronts...........................................................................................................146
COUPLINGATRAILER..........................................................................................148
UNCOUPLINGATRAILER....................................................................................150
MOVINGTHEVEHICLE—GENERALINFORMA TION...................................152
Braking...................................................................................................................152
Shifting...................................................................................................................152
EngineTemperature...............................................................................................153
Clutch(IfEquipped)..............................................................................................153
POWERTAKE-OFF(PTO)OPERA TION...............................................................157
PTOPrecautions....................................................................................................157
PTOClassication.................................................................................................158
Side-MountedPTOLocations...............................................................................158
PTOOperatingProcedures....................................................................................158
TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................159
ShiftingInstructionsforAllisonAutomaticTransmissions..................................159
MACKT306GShiftingInstructions.....................................................................159
MACKTM308ShiftingInstructions.....................................................................160
MACKTM308MShiftingInstructions.................................................................163
MACKTM309ShiftingInstructions.....................................................................165
MACKTM309MShiftingInstructions.................................................................167
MACKT309,T309LandT309LRShiftingInstructions......................................169
MACKT310ShiftingInstructions........................................................................173
MACKT310M,T310MEandT310MLRShiftingInstructions...........................176
MACKT313-T313L-T313LRShiftingInstructions.............................................180
MACKT31321,T313L21andT313LR21ShiftingInstructions..........................185
MACKT318,T318LandT318LRShiftingInstructions......................................189
MACKT31821,T318L21andT318LR21ShiftingInstructions..........................195
AXLES.......................................................................................................................201
RearAxlesOtherThanMACK.............................................................................201
MACKRearAxles.................................................................................................201
EngagingthePowerDividerLockout....................................................................202
Mack,US10EmissionsSolution.................................................................................204
DIESELPARTICULA TEFILTERS.........................................................................204
ExtendedIdlingandAftertreatmentSystemConditioning...................................206
ExhaustAftertreatmentSystem.................................................................................208
SafetyInformation.................................................................................................209
ExhaustAftertreatmentSystemComponentsand................................................210
SelectiveCatalyticReduction(SCR)....................................................................210
DieselExhaustFluid(DEF)...................................................................................212
AftertreatmentDieselParticulateFilter(DPF)......................................................214
AftertreatmentControlModule(ACM).................................................................215
AftertreatmentDPFRegeneration........................................................................215
DriverWarningsandOnBoardDiagnostics(OBD).............................................217
OnBoardDiagnostics(OBD)................................................................................217
InstrumentCluster..................................................................................................218
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MalfunctionIndicatorLamp(MIL).......................................................................219
AftertreatmentDEFTankLevel-DriverWarning&Inducement........................220
AftertreatmentDEFQuality-DriverWarning&Inducement..............................221
MisllingDieselorAftertreatmentDEFTanks.....................................................222
SCRTampering-DriverWarning&Inducement.................................................223
WarrantyandMaintenance....................................................................................224
ExhaustAftertreatmentSystemMaintenance........................................................224
EngineMaintenanceIntervals................................................................................224
MAINTENANCEANDLUBRICATION..................................................................225
MAINTENANCEINTRODUCTION.......................................................................225
TURBOCHARGER...................................................................................................225
CLEANINGYOURVEHICLE.................................................................................226
ExteriorWashing...................................................................................................226
CabandHood........................................................................................................228
Chassis...................................................................................................................228
CabInterior............................................................................................................229
Waxing...................................................................................................................229
Polishing................................................................................................................229
WinterW arnings....................................................................................................229
TOWING...................................................................................................................230
ENGINEOILLEVELCHECK.................................................................................231
PowerSteeringReservoir......................................................................................232
FUELTANK..............................................................................................................234
FuelTankCap........................................................................................................234
FUELING..................................................................................................................235
BioDiesel................................................................................................................236
B5ApprovalForMackUS10CertiedProducts..................................................236
COOLINGSYSTEM.................................................................................................238
CoolantLevelCheck..............................................................................................238
DrainingtheCoolingSystem.................................................................................239
RellingtheCoolingSystem.................................................................................239
ProtectingtheCoolingSystem..............................................................................240
CoolingSystemMaintenance................................................................................241
AccessoryDriveBeltRouting...............................................................................242
AccessoryDriveBeltRouting...............................................................................242
HEADLIGHTS..........................................................................................................244
BulbReplacement..................................................................................................244
WHEELS...................................................................................................................244
WheelInspection...................................................................................................244
Tires.......................................................................................................................245
BATTERY..................................................................................................................248
Jump-StartingEngine.............................................................................................248
ELECTRICAL...........................................................................................................249
CircuitBreakerandRelayPanels..........................................................................249
ElectricalGrease....................................................................................................253
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METRICCONVERSIONS.........................................................................................256
METRICCONVERSIONS.......................................................................................256
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SafetyInformation
IMPORTANT:Beforedrivingthis
vehicle,becertainthatyouhaveread
andthatyoufullyunderstandeachand
everystepofthedrivingandhandling
informationinthismanual.Becertain
thatyoufullyunderstandandfollowall
safetywarnings.
ITISIMPOR T 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.
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INTRODUCTION1
TOTHEOWNER
InAppreciation
ThankyouforbuyingaMACK®vehicle.Withpropercareandmaintenance,
yournewMack®T erraPro™MRUmodelwillhelpyougainacompetitive
edgewithitsfuel-efcientdrivetraincombinations,lowmaintenance,
extendedserviceintervalsand,eventually ,goodresalevalue.
TheMack®T erraPro™MRUmodelisavailableforawiderangeof
applications.Becauseofthisversatility,drivetrainsandcomponentsvaryand
operatinginstructionsmaydifferfromonemodeltoanother.Whileevery
efforthasbeenmadetocoverallcurrentarrangements,donothesitateto
consultyourMACKdistributorifaquestionarises.Honest,personalservice
isstandardwitheveryMACKsale.
CAUTION
MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin
thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.
We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack®
TerraPro™model,andthatyouseemanyyearsoftrouble-freedriving.
Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations
applicableatthetimeofmanufacture.
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2INTRODUCTION
AboutThisHandbook
ThishandbookisreferredtoastheMack®T erraPro™SeriesOperator’s
Handbook.ItcoversallMack®TerraPro™models.Keepthishandbookwith
thevehicleatalltimestoensurethateachownerand/oroperatorwillhave
accesstoallpertinentinformationrelatingtotheoperationandhandlingof
thisvehicle.
Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation
concerningthedailyoperationofthisvehicle.Pleasereaditthoroughly;
payparticularattentiontoadvisorylabelsthathavebeenincludedtodraw
attentiontoimportantissuesofoperatorsafetyandoverallperformance.
Informationandillustrationsinthishandbookarebasedonthelatest
productionusageatthetimeofprintingandaresubjecttochangewithout
priornotice.
Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual
beginningwith“MAINTENANCEINTRODUCTION”,page225.Forfurther
information,refertotheMaintenanceandLubricationManual.Otherimportant
informationcanbefoundintheEmissionControlSystemsforMACKDieselEngine
Manual.
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INTRODUCTION3
THEVEHICLE
BasicConguration
TheMack®T erraPro™MRUmodelhasalow-entry,cab-forward-style
operatorscompartment.Lowproleandexcellentvisibilitymakethismodel
popularthroughouttherefuse-hauling,constructionandreghtingindustries.
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.
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4INTRODUCTION
COMPONENTIDENTIFICATION
Locatethefollowingserialnumbersandwritethemintheboxesprovided
nexttoeachillustration.
VINLocations
TheV ehicleIdenticationNumber(VIN)isdisplayedintwolocations(aframe
railstampingandalabel).The17-digitVINmustbeidenticalinbothlocations.
TheVINframestampingislocatedontherightoutsideframerailandthe
leftinsideframerail.
C0029554
TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.
C0028941
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INTRODUCTION5
EngineIdentication
OntheMACKMPengines,theengineserialnumberisstampedontheleft
sideoftheengineblock,belowtheinletmanifold.
C0028943
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6INTRODUCTION
EngineInformationPlate
IncompliancewithFederalandCaliforniaemissionrequirements,an
engineinformationlabelisafxedtoallMACKdieselengines.Thislabel,
whichislocatedonthecylinderheadcoveratthefrontoftheengine,gives
basicengineidenticationinformation(enginemodel,serialnumber,etc.),
advertisedhorsepoweratratedspeed,emissionsregulationstowhichthe
engineconformsandinletandexhaustvalvelashsettings.Examplesofthe
49stateEPAapproved,and50stateEPAandCaliforniaapprovedengine
identicationlabelsaregivenbelow.
W2040455
EngineIdenticationLabel-49StateEPAApprovedEngine
withoutCalifornia"CleanIdle"
EngineIdenticationLabel-50StateEPAApprovedEngine
withCalifornia"CleanIdle"
W2040456
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INTRODUCTION7
CleanIdleEngines
TheCaliforniaAirResourcesBoard(ARB)requiresthat2008andlatermodel
yearvehiclesbeequippedwithengineshavingtamper-resistantsoftware
whichlimitsthetimeatwhichtheenginecanidleatspeedsabovelowidle
(550–700rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idle
timewillbelimitedtoveminutes,afterwhichtheenginewillrevertback
tolowidle.V ehiclesequippedwithaCleanIdleengineareidentiedbya
labelwhichisafxedtothelowerportionofthedriver’ssidedooroncab-over
models(MRU).
CleanIdleEngineLabel
W2056289
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8INTRODUCTION
TransmissionIdentication
TheMACKT300Seriestransmissionserialnumberislocatedontherear
leftsideofthemaincase.
C0028947
TheAllisonRDSandEVStransmissionidenticationplateislocatedonthe
rearrightsideofthemaincase,nearthelowerend.
C0029555
TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside
ofthehousing.
C0028950
TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe
axlehousingtowardthecarrier.
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INTRODUCTION9
C0028951
TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft
sideoftheforwardcarrier,andthetopoftherearcarrier.
C0028952
TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof
therearaxlehousing,nexttothecarrier.
C0028953
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10INTRODUCTION
TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof
theforwardcarrier,andthetopoftherearcarrier.
C0028954
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INTRODUCTION11
WARRANTYINFORMATION
ThischassisisequippedwithaUS2010emissioncompliantengineandan
exhaustaftertreatmentsystem(DieselParticulateFilter).UseofUltraLow
SulfurDiesel(ULSD)fuelandEO-OPremiumPlus(orVDS-4)specication
highperformancedieselengineoilisrequiredinthisvehicle.
Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand
aftertreatmentsystemwarranty.
AirBrakeSystem
TheMACKStandardVehicleWarrantyappliestotheairbrakesystem,as
setforthintheWarranty,butonlyiftheairbrakesystemhasnotbeen
subjectedtounauthorizedadditions,deletionsormodications.Ifanysuch
unauthorizedadditions,deletionsormodicationsareperformed,Mack
Trucks,Inc.disclaimsanyandallliabilityforanylossordamagearisingoutof
amalfunctionoftheairbrakesystem.
Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable
federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.
Tractorairsystemsaredesignedforoperationasatractoronly,andtruckair
systemsaredesignedtobeoperatedasatruckonly .Ifatractorisgoingtobe
convertedforoperationasatruck,theairbrakesystemmustberecongured
tothatofatruck.Conversely,ifatruckisgoingtobeconvertedforoperation
asatractor,theairbrakesystemmustbereconguredtothatofatractor.
ConsultyourlocalMACKdistributorforadditionalinformation.
Ifanyunauthorizedadditions,deletionsormodicationsaremadetoany
portionoftheairbrakesystemwhichisrequiredbyFederalMotorVehicle
SafetyStandards,MackTrucks,Inc.makesnorepresentationastoconformity
withtheStandards.
Forcompletewarrantyinformation,refertothePedigreedProtectionPlan
providedwitheachvehicle.
ENGINEGASEOUSEMISSIONCONTROL
SYSTEMS
WARRANTYMAINTENANCE
Note:Foremissioncontrolsystems
informationonenginesotherthanMACK,
refertotheenginevendor’spublication
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12INTRODUCTION
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS
WARRANTY
MackTrucks,Inc.warrantstheEmission
ControlSystemsoneachnewMack
dieselengineinanewMackTruckto
complywithallUnitedStatesFederal
andCanadianemissionsregulations
applicableatthetimeofmanufactureof
theengine,andtobefreefromdefects
inmaterialandworkmanshipunder
normaluseandserviceupto60months,
or160934km(100,000miles),which
everoccursrst,providedthatallMack
Trucks,Inc.maintenancerequirements
arefollowedasdescribedinthismanual.
Allwarrantyperiodsarecalculatedfrom
thedate-in-serviceofthenewvehicle.
Therepairorreplacementofdefective
partswillbemadewithoutchargefor
thecostofpartsandifrepairsaremade
atanauthorizedMackTrucks,Inc.
dealership,therewillbenochargefor
labor.MackTrucks,Inc.’sobligation
underthiswarrantyislimitedtotherepair
orreplacement,atMackTrucks,Inc.’s
option,ofanypart(s)oftheEmission
ControlSystemsofsuchengineand/or
vehiclefoundtobedefectiveupon
examinationbyMackTrucks,Inc.and
providedthatsuchpart(s)werereturnedto
MackTrucks,Inc.oritsnearestauthorized
Dealerwithinareasonableperiodoftime.
QualicationsandLimitations:
Note:NotcoveredbytheEmissions
ControlSystemsW arranty:
•Malfunctionscausedbymisuse,
improperadjustments,modication,
alteration,tampering,disconnection,
improperorinadequatemaintenance
anduseofimproperdieselfuelorDEF .
•Inconvenience,lossofuseofthe
vehicle,commerciallossofany
kindincluding,butnotlimitedto,
consequentialorincidentaldamages
•Anyvehicleinwhichtheodometer
hasbeenalteredordamagedsothat
mileagecannotbereadilydetermined.
•Damageresultingfromaccident,acts
ofnatureorothereventsbeyondthe
controlofMackTrucks,Inc.
THISW ARRANTYISEXPRESSL YINLIEUOFALLOTHERW ARRANTIES
ANDREPRESENTATIONSORCONDITIONS,STA TUTORYOR
OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED
TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA
PARTICULARPURPOSE.
EmissionsControlSystemWarranty
Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.
1TurbochargerAssembly
•VGTActuator
2ChargeAirCooler
•CACHoses
3EngineControlModule(ECM)
4Injectors
•CACPipes(Airinletto/fromCAC)
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg18.png)
INTRODUCTION13
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
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg19.png)
14INTRODUCTION
•AftertreatmentOutletNOx
•AftertreatmentIntakeNOx
•EGRDifferentialPressure
•AmbientAirTemperature(AA T)
18SCR
•AftertreatmentSelectiveCatalytic
Reduction(SCR)Catalyst
•AftertreatmentDieselExhaustFluid
(DEF)Pump
•AftertreatmentDEFDosing
AbsolutePressureSensor
•AftertreatmentDEFReturn
Valve
•AftertreatmentDEFDosingV alve
•AftertreatmentDEFTank
•AftertreatmentDEFTank
Heater/Sender
ENGINEGASEOUSEMISSIONSCONTROL
SYSTEMWARRANTY
•AftertreatmentDEFTankHeater
•AftertreatmentDEFTankHeater
Valve
•AftertreatmentDEFTank
TemperatureSensor
•AftertreatmentDEFLevelSensor
•AftertreatmentDEFHeatedLines
19.InstrumentCluster(Repairof
microprocessor,OBDMIL,RealTime
Clock,AftertreatmentDEFTankGauge
and,AftertreatmentDEFTankLowLevel
Indicator)
20.ExhaustGasPiping(from
TurbochargertoAftertreatmentSystem)
21.DataLinkConnector(DLC)
Theemissionwarrantyforthediesel
particulatelter(DPF)andSCRSystem
coversdefectsinworkmanshiponly.
Normalmaintenance,suchascleaning
ashfromthelteratregularmaintenance
intervalsandcleaningtheaftertreatment
fuelinjectoronDieseloxidationcatalyst
(DOC)DPFsystems,isnotcoveredby
theemissionwarranty.WiththeThermal
regeneratorDPFsystem,cleaningthe
ignitionelectrodesandfuelinjection
nozzleattheregularmaintenanceintervals
isconsiderednormalmaintenanceandnot
coveredbytheemissionwarranty .
Note:Inresponsetocustomerrequests,
MackTrucks,Inc.maybuildvehicleswith
enginessuppliedbyothermanufacturers.
Inthesecases,eachenginemanufacturer
throughitsserviceorganization,is
responsibleforemissioncontrolsystems
warrantyonallpartsoftheengine
assembly,asfurnished.
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg1a.png)
FEDERALEMISSIONREQUIREMENTS
INTRODUCTION15
Thissectioncoverstherequirementofthe
UnitedStatesCleanAirActwhichstates:
“Themanufacturershallfurnishwith
eachnewmotorvehicleormotorvehicle
enginesuchwritteninstructionsforthe
maintenanceanduseofthevehicleor
enginebytheultimatepurchaserasmay
TAMPERINGWITHGASEOUSEMISSIONCONTROLSYSTEMS
PROHIBITED
TheFederalCleanAirActprohibitsthe
removalorrenderinginoperativeofany
deviceorelementofdesigninstalledonor
inamotorvehicleormotorvehicleengine
incompliancewithFederalEmission
Regulationsby:
1Anypersonpriortoitssaleanddelivery
totheultimatepurchaser,or
2Anymanufacturerordistributorafter
itssaleanddeliverytotheultimate
purchaser,or
3Anypersonengagedinthebusinessof
repairing,servicing,selling,leasing,or
bereasonableandnecessarytoassurethe
properfunctioningofemissioncontrol
devicesandsystems.”Thissectionalso
coverstherequirementsoftheemissions
regulationspromulgatedundertheMotor
VehicleSafetyActinCanada.
4Anypersonwhooperatesaeetof
Note:Forspecicsoftheprohibited
vehicle/enginemodicationsreferto
theMackTrucks,Inc.BodyBuilders
documentation.
tradingmotorvehiclesormotorvehicle
enginesfollowingitssaleanddelivery
totheultimatepurchaser,or
motorvehiclesfollowingitssaleand
deliverytotheultimatepurchaser.
EMISSIONCONTROLSYSTEMSWARRANTY—
CALIFORNIA
TheCaliforniaAirResourcesBoardand
MackTrucks,Inc.arepleasedtoexplain
theCaliforniaemissioncontrolsystem
warrantyonyournewmotorvehicle
engine.InCalifornia,newmotorvehicle
enginesmustbedesigned,builtand
equippedtomeettheState’sstringent
anti-smogstandards.MackTrucks,Inc.
mustwarranttheemissioncontrolsystem
onyourenginefortheperiodoftimelisted
belowprovidedtherehasbeennoabuse,
neglect,orimpropermaintenanceofyour
engine.
Youremissioncontrolsystemmay
includepartssuchasthefuel-injection
system,turbochargerassembly,electronic
controlmoduleandotheremission-related
assemblies.
Whereawarrantableconditionexists,
MackTrucks,Inc.willrepairyourengine
atnocosttoyouincludingdiagnosis,
parts,andlabor.
MANUFACTURER’SW ARRANTY
COVERAGE:
Ifanemission-relatedpartofyourengine
isdefective,thepartwillberepairedor
replacedbyMackTrucks,Inc.Thisis
youremissioncontrolsystemDEFECTS
WARRANTY .
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg1b.png)
16INTRODUCTION
OWNER’SWARRANTYRESPONSIBILITIES:
Asthemotorvehicleengineowner,you
areresponsiblefortheperformanceof
therequiredmaintenancelistedinthis
manual.MackTrucks,Inc.recommends
thatyouretainallreceiptscovering
maintenanceofyourvehicle,butMack
Trucks,Inc.cannotdenywarrantysolely
forthelackofreceiptsorforyourfailure
toensuretheperformanceofallscheduled
maintenancelistedinothermanualswhich
weresuppliedwithyourvehicle.
Youareresponsibleforpresenting
yourmotorvehicleenginetoaMACK
dealerassoonasaproblemexists.The
warrantyrepairsshouldbecompleted
inareasonableamountoftime,notto
exceed30days.Asthemotorvehicle
engineowner,youshouldalsobeaware
thatMackTrucks,Inc.maydenyyou
warrantycoverageifyourvehicleora
parthasfailedduetoabuse,neglect,
impropermaintenance,orunapproved
modications.
Ifyouhaveanyquestionsregarding
yourwarrantyrightsandresponsibilities,
youshouldcontacttheMackTrucks,
Inc.WarrantyActivitiesP.O.Box26259,
Greensboro,NC27402,ortheCalifornia
AirResourcesBoardat9480Telstar
Avenue,ElMonte,California91731.
(Applicableonlytovehiclesand/or
enginescertiedforsaleandregistered
intheStateofCalifornia)MackTrucks,
Inc.warrantstheEmissionControl
SystemsoneachnewMACKdiesel
engineinanewMACKtrucktocomply
withallStateofCaliforniaemissions
regulationsapplicableatthetimeof
manufactureoftheengine,andtobefree
fromdefectsinmaterialandworkmanship
undernormaluseandserviceupto
60months,or100,000miles,or3,000
engineoperatinghours,whicheveroccurs
rst,providedthatallMackTrucks,
Inc.maintenancerequirementsare
followedasdescribedinthismanual.All
warrantyperiodsarecalculatedfromthe
date-in-serviceofthenewvehicle.The
repairorreplacementofdefectiveparts
willbemadewithoutchargeforthecost
ofpartsand,ifrepairsaremadeatan
authorizedMackTrucks,Inc.dealership,
therewillbenochargeforlabor.
MackTrucks,Inc.’sobligationunder
thiswarrantyislimitedtotherepair
orreplacement,atMackTrucks,Inc.’s
option,ofanypart(s)ofEmissionControl
Systemsofsuchengineand/orvehicle
foundtobedefectiveuponexaminationby
MackTrucks,Inc.andprovidedthatsuch
part(s)werereturnedtoMackTrucks,Inc.
oritsnearestauthorizedDealerwithina
reasonableperiodoftime.
QualicationsandLimitations:
NotcoveredbytheEmissionsControl
SystemsW arranty:
•Malfunctionscausedbymisuse,
improperadjustments,modication,
alteration,tampering,disconnection,
improperorinadequatemaintenance
anduseofimproperdieselfuelorDEF .
•Damageresultingfromaccident,acts
ofnatureorothereventsbeyondthe
controlofMackTrucks,Inc.
•Inconvenience,lossofuseofthe
vehicle,commerciallossofany
kindincluding,butnotlimitedto,
consequentialorincidentaldamages.
•Anyvehicleinwhichtheodometer
hasbeenalteredordamagedsothat
mileagecannotbereadilydetermined.
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg1c.png)
INTRODUCTION17
THISW ARRANTYISEXPRESSL YINLIEUOFALLOTHERW ARRANTIES
ANDREPRESENTATIONSORCONDITIONS,STA TUTORYOR
OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED
TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA
PARTICULARPURPOSE.
EmissionsControlSystemWarranty
Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheCaliforniacodeofregulations.
1TurbochargerAssembly
•VGTActuator
2ChargeAirCooler
•CACPipes(Airinletto/fromCAC)
•CACHoses
3EngineControlModule(ECM)
4Injectors
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
•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
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg1d.png)
18INTRODUCTION
•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
•AftertreatmentDEFTank
Heater/Sender
•AftertreatmentDEFTankHeater
•AftertreatmentDEFTankHeater
Valve
•AftertreatmentDEFTank
TemperatureSensor
•AftertreatmentDEFLevelSensor
•AftertreatmentDEFHeatedLines
19.InstrumentCluster(Repairof
microprocessor,OBDMIL,RealTime
Clock,AftertreatmentDEFTankGauge
and,AftertreatmentDEFTankLowLevel
Indicator)
20.ExhaustGasPiping(from
TurbochargertoAftertreatmentSystem)
21.DataLinkConnector(DLC)
![](/html/1e/1e34/1e3493318422f652952f12f386fb7306f1a398e686d786782fa86c02f6b0ef8a/bg1e.png)
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS
WARRANTY—Continued
Theemissionwarrantyforthediesel
particulatelter(DPF)andSCRSystem
coversdefectsinworkmanshiponly.
Normalmaintenance,suchascleaning
ashfromthelteratregularmaintenance
intervalsandcleaningtheaftertreatment
fuelinjectoronDieseloxidationcatalyst
(DOC)DPFsystems,isnotcoveredby
theemissionwarranty.WiththeThermal
regeneratorDPFsystem,cleaningthe
ignitionelectrodesandfuelinjection
nozzleattheregularmaintenanceintervals
isconsiderednormalmaintenanceandnot
coveredbytheemissionwarranty .
Note:Inresponsetocustomerrequests,
MackTrucks,Inc.maybuildvehicleswith
enginessuppliedbyothermanufacturers.
Inthesecases,eachenginemanufacturer
throughitsserviceorganization,is
responsibleforemissioncontrolsystems
warrantyonallpartsoftheengine
assembly,asfurnished.
CAUTION
Anyunauthorizedadjustmentstothe
emissioncontrolcomponentscancause
severedamagetotheengine.
INTRODUCTION19
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
specied,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