MACK MRU User Manual

Mack

MRU Series

Mack® TerraProTM Series

(MRU Series)

Mack® TerraProTM Series

(MRU Series)

21394655

21394655 21394655

Printed in U.S.A.

April 2010

Foreword

Thismanualcontainsinformationconcerningtheoperationand functionoftheMackLinkSystem.Theinformationinthismanual appliestovehiclesbuilt April2010andlater.Pleasekeepthismanual inthevehicleatalltimes.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay differslightlyfromtheactualvehicle.However,keycomponents addressedinthisdocumentarerepresentedasaccuratelyaspossible.

TheNationalHighwayTrafcSafetyAdministration(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

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

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

WARRANTYINFORMA TION..................................................................................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

SafetyCerticationLabel........................................................................................29

ADVISORYLABELS.................................................................................................31

AdvisoryLabelLocations(OnV ehicle)..................................................................31

TRUCK-TRACTORCONSPICUITY.........................................................................39

CABENTRY/EXIT.....................................................................................................40

Three-LimbContact.................................................................................................40

DriverSide...............................................................................................................42

PassengerSide.........................................................................................................44

DeckPlateAccess....................................................................................................46

SAFETYTIPSFORCOLDWEA THEROPERA TION.............................................48

DriverVisibility.......................................................................................................48

CabDoorSealsandKeyLocks...............................................................................49

OutsideMirrorHeater..............................................................................................49

AirHornSnowShield..............................................................................................50

EmergencyReectorKit..........................................................................................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

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

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

PTOClassication.................................................................................................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

MalfunctionIndicatorLamp(MIL).......................................................................219

AftertreatmentDEFTankLevel-DriverWarning&Inducement........................220

AftertreatmentDEFQuality-DriverWarning&Inducement..............................221

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

B5ApprovalForMackUS10CertiedProducts..................................................236

COOLINGSYSTEM.................................................................................................238

CoolantLevelCheck..............................................................................................238

DrainingtheCoolingSystem.................................................................................239

RellingtheCoolingSystem.................................................................................239

ProtectingtheCoolingSystem..............................................................................240

CoolingSystemMaintenance................................................................................241

AccessoryDriveBeltRouting...............................................................................242

HEADLIGHTS..........................................................................................................244

BulbReplacement..................................................................................................244

WHEELS...................................................................................................................244

WheelInspection...................................................................................................244

Tires.......................................................................................................................245

BATTERY..................................................................................................................248

Jump-StartingEngine.............................................................................................248

ELECTRICAL...........................................................................................................249

CircuitBreakerandRelayPanels..........................................................................249

ElectricalGrease....................................................................................................253

METRICCONVERSIONS.........................................................................................256

METRICCONVERSIONS.......................................................................................256

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.

INTRODUCTION1

TOTHEOWNER

InAppreciation

ThankyouforbuyingaMACK®vehicle.Withpropercareandmaintenance,

yournewMack®T erraPro™MRUmodelwillhelpyougainacompetitive

edgewithitsfuel-efcientdrivetraincombinations,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.

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.

INTRODUCTION3

THEVEHICLE

BasicConguration

TheMack®T erraPro™MRUmodelhasalow-entry,cab-forward-style operatorscompartment.Lowproleandexcellentvisibilitymakethismodel popularthroughouttherefuse-hauling,constructionandreghtingindustries.

VehicleManagementandControlSystem (V-MAC®)

TheVehicleManagementandControlSystem(V-MAC)isanelectronic controlsystemthatmanagesengineandvehiclefunctions.Inaddition,the DataMax™portionofV-MACmonitorsandstoresavarietyofinformation(i.e., maintenanceschedules,overspeedlogs,faulttables,tripsummaries)

ForacompletedescriptionoftheV-MACIVsystem,refertotheapplicable V-MAC®Operator’sGuide,whichissuppliedwiththevehicle.

Additionalinformationconcerningservice,diagnostics,programmingand vendorequipmentinterfaceapplicationisavailablefromtheMackTrucks,Inc. ServicePublicationsDepartment.ContactyourlocalMACKdealerfordetails.

WARNING

NevercutintotheV-MACsystemwireharnesstopoweradditionalequipment.If suchequipmentistobeinstalled,contactyourMACKdealerforassistance.

4INTRODUCTION

COMPONENTIDENTIFICATION

Locatethefollowingserialnumbersandwritethemintheboxesprovided nexttoeachillustration.

VINLocations

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

TheVINframestampingislocatedontherightoutsideframerailandthe leftinsideframerail.

C0029554

TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.

C0028941

INTRODUCTION5

EngineIdentication

OntheMACKMPengines,theengineserialnumberisstampedontheleft sideoftheengineblock,belowtheinletmanifold.

C0028943

6INTRODUCTION

EngineInformationPlate

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

W2040455

EngineIdenticationLabel-49StateEPAApprovedEngine

withoutCalifornia"CleanIdle"

EngineIdenticationLabel-50StateEPAApprovedEngine

withCalifornia"CleanIdle"

W2040456

INTRODUCTION7

CleanIdleEngines

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

CleanIdleEngineLabel

W2056289

8INTRODUCTION

TransmissionIdentication

TheMACKT300Seriestransmissionserialnumberislocatedontherear leftsideofthemaincase.

C0028947

TheAllisonRDSandEVStransmissionidenticationplateislocatedonthe rearrightsideofthemaincase,nearthelowerend.

C0029555

TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside ofthehousing.

C0028950

TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe axlehousingtowardthecarrier.

INTRODUCTION9

C0028951

TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft sideoftheforwardcarrier,andthetopoftherearcarrier.

C0028952

TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof therearaxlehousing,nexttothecarrier.

C0028953

10INTRODUCTION

TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof theforwardcarrier,andthetopoftherearcarrier.

C0028954

INTRODUCTION11

WARRANTYINFORMATION

ThischassisisequippedwithaUS2010emissioncompliantengineandan exhaustaftertreatmentsystem(DieselParticulateFilter).UseofUltraLow SulfurDiesel(ULSD)fuelandEO-OPremiumPlus(orVDS-4)specication highperformancedieselengineoilisrequiredinthisvehicle.

Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand aftertreatmentsystemwarranty.

AirBrakeSystem

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

Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.

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

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

Forcompletewarrantyinformation,refertothePedigreedProtectionPlan providedwitheachvehicle.

ENGINEGASEOUSEMISSIONCONTROL SYSTEMS

WARRANTYMAINTENANCE

Note:Foremissioncontrolsystems informationonenginesotherthanMACK, refertotheenginevendor’spublication

12INTRODUCTION

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY

MackTrucks,Inc.warrantstheEmission ControlSystemsoneachnewMack dieselengineinanewMackTruckto complywithallUnitedStatesFederal andCanadianemissionsregulations applicableatthetimeofmanufactureof theengine,andtobefreefromdefects inmaterialandworkmanshipunder normaluseandserviceupto60months, or160934km(100,000miles),which everoccursrst,providedthatallMack Trucks,Inc.maintenancerequirements arefollowedasdescribedinthismanual. Allwarrantyperiodsarecalculatedfrom thedate-in-serviceofthenewvehicle.

Therepairorreplacementofdefective partswillbemadewithoutchargefor thecostofpartsandifrepairsaremade atanauthorizedMackTrucks,Inc. dealership,therewillbenochargefor labor.MackTrucks,Inc.’sobligation underthiswarrantyislimitedtotherepair orreplacement,atMackTrucks,Inc.’s option,ofanypart(s)oftheEmission ControlSystemsofsuchengineand/or vehiclefoundtobedefectiveupon examinationbyMackTrucks,Inc.and providedthatsuchpart(s)werereturnedto MackTrucks,Inc.oritsnearestauthorized Dealerwithinareasonableperiodoftime.

QualicationsandLimitations:

Note:NotcoveredbytheEmissions ControlSystemsW arranty:

•Malfunctionscausedbymisuse,

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

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

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

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACHoses

3EngineControlModule(ECM)

4Injectors

•CACPipes(Airinletto/fromCAC)

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

14INTRODUCTION

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AA T)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFTank

Heater/Sender

ENGINEGASEOUSEMISSIONSCONTROL SYSTEMWARRANTY

•AftertreatmentDEFTankHeater

Valve

•AftertreatmentDEFTank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

19.InstrumentCluster(Repairof microprocessor,OBDMIL,RealTime Clock,AftertreatmentDEFTankGauge and,AftertreatmentDEFTankLowLevel Indicator)

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

Theemissionwarrantyforthediesel particulatelter(DPF)andSCRSystem coversdefectsinworkmanshiponly. Normalmaintenance,suchascleaning ashfromthelteratregularmaintenance intervalsandcleaningtheaftertreatment fuelinjectoronDieseloxidationcatalyst (DOC)DPFsystems,isnotcoveredby theemissionwarranty.WiththeThermal regeneratorDPFsystem,cleaningthe ignitionelectrodesandfuelinjection nozzleattheregularmaintenanceintervals

isconsiderednormalmaintenanceandnot coveredbytheemissionwarranty .

Note:Inresponsetocustomerrequests, MackTrucks,Inc.maybuildvehicleswith enginessuppliedbyothermanufacturers. Inthesecases,eachenginemanufacturer throughitsserviceorganization,is responsibleforemissioncontrolsystems warrantyonallpartsoftheengine assembly,asfurnished.

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.

4Anypersonwhooperatesaeetof

Note:Forspecicsoftheprohibited vehicle/enginemodicationsreferto theMackTrucks,Inc.BodyBuilders documentation.

tradingmotorvehiclesormotorvehicle enginesfollowingitssaleanddelivery totheultimatepurchaser,or

motorvehiclesfollowingitssaleand deliverytotheultimatepurchaser.

EMISSIONCONTROLSYSTEMSWARRANTY— CALIFORNIA

TheCaliforniaAirResourcesBoardand MackTrucks,Inc.arepleasedtoexplain theCaliforniaemissioncontrolsystem warrantyonyournewmotorvehicle engine.InCalifornia,newmotorvehicle enginesmustbedesigned,builtand equippedtomeettheState’sstringent anti-smogstandards.MackTrucks,Inc. mustwarranttheemissioncontrolsystem onyourenginefortheperiodoftimelisted belowprovidedtherehasbeennoabuse, neglect,orimpropermaintenanceofyour engine. Youremissioncontrolsystemmay includepartssuchasthefuel-injection

system,turbochargerassembly,electronic controlmoduleandotheremission-related assemblies. Whereawarrantableconditionexists, MackTrucks,Inc.willrepairyourengine atnocosttoyouincludingdiagnosis, parts,andlabor.

MANUFACTURER’SW ARRANTY COVERAGE:

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

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

(Applicableonlytovehiclesand/or enginescertiedforsaleandregistered

intheStateofCalifornia)MackTrucks,

Inc.warrantstheEmissionControl SystemsoneachnewMACKdiesel engineinanewMACKtrucktocomply withallStateofCaliforniaemissions regulationsapplicableatthetimeof manufactureoftheengine,andtobefree fromdefectsinmaterialandworkmanship undernormaluseandserviceupto 60months,or100,000miles,or3,000 engineoperatinghours,whicheveroccurs rst,providedthatallMackTrucks, Inc.maintenancerequirementsare followedasdescribedinthismanual.All warrantyperiodsarecalculatedfromthe date-in-serviceofthenewvehicle.The repairorreplacementofdefectiveparts willbemadewithoutchargeforthecost ofpartsand,ifrepairsaremadeatan authorizedMackTrucks,Inc.dealership, therewillbenochargeforlabor. MackTrucks,Inc.’sobligationunder thiswarrantyislimitedtotherepair orreplacement,atMackTrucks,Inc.’s option,ofanypart(s)ofEmissionControl Systemsofsuchengineand/orvehicle foundtobedefectiveuponexaminationby MackTrucks,Inc.andprovidedthatsuch part(s)werereturnedtoMackTrucks,Inc. oritsnearestauthorizedDealerwithina reasonableperiodoftime.

QualicationsandLimitations:

NotcoveredbytheEmissionsControl SystemsW arranty:

•Malfunctionscausedbymisuse,

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

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

INTRODUCTION17

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

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

Heater/Sender

•AftertreatmentDEFTankHeater

Valve

•AftertreatmentDEFTank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

19.InstrumentCluster(Repairof microprocessor,OBDMIL,RealTime Clock,AftertreatmentDEFTankGauge and,AftertreatmentDEFTankLowLevel Indicator)

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY—Continued

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 specied,orbrokenfastenerseals,the costofrepairingsuchdamageWILL NOTBECOVEREDunderwarranty

1.RepairsbyMACKDealers,

Sub-DealersandServiceDealers

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

2.InanEmergency Inanemergency,whereanauthorized MACKfacilityisnotavailable,repairs maybeperformedatanyavailableservice

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

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

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