Mack Pinnacle CHU Operator Manual

Mack

CHU Series

Mack

Pinnacle

Series

(CHU Series)

Mack® Pinnacle

Series

(CHU Series)

21394649

April 2010

Foreword

Thismanualcontainsinformationconcerningtheandfunctionofthe MackLinkSystem.Theinformationinthismanualappliestovehicles builtApril2010andlater.Pleasekeepthismanualinthevehicleat alltimes.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay differslightlyfromtheactualvehicle.However,keycomponents addressedinthisdocumentarerepresentedasaccuratelyaspossible.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)and MackTrucksInc.shouldbeinformedimmediatelyifyoubelievethat thevehiclehasadefectthatcouldcauseacrash,injuryordeath.

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

MackTrucks,Inc.

Greensboro,NCUSA

Ordernumber:PV776-21394649

Allrightsreserved.Nopartofthispublicationmaybereproduced, storedinretrievalsystem,ortransmittedinanyformsbyanymeans, electronic,mechanical,photocopying,recordingorotherwise,without thepriorwrittenpermissionofMackTrucks,Inc.

Contents

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

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

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

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

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

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

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

COMPONENTIDENTIFICA TION..............................................................................4

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

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

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

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

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

WARRANTYINFORMA TION..................................................................................11

AirBrakeSystem.....................................................................................................11

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

EmissionsControlSystemW arranty.......................................................................13

ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............15

FEDERALEMISSIONREQUIREMENTS............................................................16

EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................16

EmissionsControlSystemW arranty.......................................................................18

SERVICELITERA TURE............................................................................................22

MACKClass8–ComponentsServiceManual.......................................................22

Class8–CustomCollatedServiceManualonCD.................................................22

CUSTOMERSERVICE..............................................................................................23

Call1-800-866-1177forMACKOne-Call™..........................................................23

QuestionsandComplaints.......................................................................................23

Addresses.................................................................................................................24

AdditionalAssistance..............................................................................................25

REPORTINGSAFETYDEFECTS.............................................................................26

UnitedStates............................................................................................................26

Canada......................................................................................................................26

Mexico.....................................................................................................................26

EVENTDA T ARECORDINGDEVICES...................................................................27

SAFETYINFORMATION...........................................................................................28

SAFETYSTA TEMENT..............................................................................................28

CERTIFICA TIONLABELS........................................................................................30

SafetyCerticationLabel........................................................................................30

ADVISORYLABELS.................................................................................................32

AdvisoryLabelLocations(OnV ehicle)..................................................................32

TRUCK-TRACTORCONSPICUITY.........................................................................43

CABENTRY/EXIT.....................................................................................................44

Three-LimbContact.................................................................................................44

DriverSide...............................................................................................................46

PassengerSide.........................................................................................................48

DeckPlateAccess....................................................................................................50

SAFETYTIPSFORCOLDWEA THER...................................................................52

DriverVisibility.......................................................................................................52

AuxiliaryCabHeater...............................................................................................53

CabDoorSealsandKeyLocks...............................................................................54

OutsideMirrorHeater..............................................................................................54

AirHornSnowShield..............................................................................................55

EmergencyReectorKit..........................................................................................55

FireExtinguisher(Optional)....................................................................................55

INSTRUMENTSANDCONTROLS...........................................................................56

CABINTERIOR..........................................................................................................56

INSTRUMENTPANEL..............................................................................................57

Tell-T ales..................................................................................................................57

PanelArrangement...................................................................................................58

INSTRUMENTPANELGAUGELA YOUT..............................................................59

PanelA.....................................................................................................................61

PanelB.....................................................................................................................62

PanelC.....................................................................................................................64

PanelD.....................................................................................................................65

FunctionofOptionalSwitches.................................................................................78

CABCLIMA TECONTROL.......................................................................................85

SLEEPERCLIMA TECONTROL..............................................................................87

LIGHTCONTROLP ANEL........................................................................................88

LOWERCONSOLEP ANEL......................................................................................89

STEERINGCOLUMN................................................................................................90

CombinationStarterandElectricalSwitch..............................................................90

SteeringWheelAdjustment.....................................................................................90

TurnSignalLever....................................................................................................91

StalkSwitch(IfEquipped,Co-Pilot®Only)...........................................................92

FLOORPEDALS........................................................................................................93

MISCELLANEOUSCONTROLS..............................................................................94

DomeLight..............................................................................................................94

InteriorCabLights(SleeperCab)............................................................................95

AirHorn...................................................................................................................95

FreshAirV ent..........................................................................................................96

CabAirFilter...........................................................................................................97

Microphone..............................................................................................................98

AccessoryPowerOutlets.........................................................................................99

.......................................................................................................................................102

PRE-TRIPINSPECTIONANDDAIL YMAINTENANCE.....................................102

Pre-TripInspectionQuickList..............................................................................103

NewV ehicleBreak-In............................................................................................114

WINDSHIELDW ASHERRESER VOIR..................................................................117

HOOD.......................................................................................................................118

OpeningtheHood..................................................................................................118

ClosingtheHood...................................................................................................120

LockingtheHood..................................................................................................121

HOSETENDERS......................................................................................................122

DOORS......................................................................................................................123

StandardDoorPanel..............................................................................................123

PowerDoorPanel(Optional).................................................................................124

OpeningtheCabDoor...........................................................................................125

LockingtheCabDoor............................................................................................125

PowerWindowRegulators....................................................................................125

REMOTEKEYLESSENTRY—(OPTIONAL)......................................................126

TransmitterOperations..........................................................................................127

BatteryReplacement..............................................................................................128

SEATBEL TS.............................................................................................................131

SeatBeltOperation................................................................................................131

FasteningSeatBelt................................................................................................131

AdjustableD-RingShoulderBelts(ifequipped)...................................................133

Komfort®LatchSystem........................................................................................134

SLEEPERBUNKRESTRAINT...............................................................................136

UpperBunk(Optional)..........................................................................................136

BunkRestraint......................................................................................................137

BunkRestraintMaintenance..................................................................................137

SEATADJUSTMENTANDRECLINE(IFEQUIPPED)........................................138

HEATEDSEA T(OPTIONAL)..................................................................................138

SWIVELSEA T(OPTIONAL)..................................................................................138

MACKENGINEINFORMA TION...........................................................................141

PrecautionsandWarnings......................................................................................141

EngineModelDesignations...................................................................................142

CRUISECONTROL................................................................................................143

SpeedControlSwitches.........................................................................................143

SettingCruiseControl...........................................................................................144

DisengagingCruiseControl...................................................................................144

MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................145

EngineBrakeSwitch..............................................................................................146

HowtheEngineBrakeisActivated.......................................................................147

CruiseControlwiththeMACKPowerLeash™EngineBrake.............................148

ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........149

OverFlatTerrain....................................................................................................149

DescendingaGrade...............................................................................................150

OnSlipperyRoadSurfaces....................................................................................152

BRAKE.....................................................................................................................154

AirBrakeSystem...................................................................................................154

AutomaticSlackAdjusters....................................................................................155

ParkingBrakeSystem............................................................................................156

ParkingBrake........................................................................................................156

Parking...................................................................................................................156

Anti-LockBrakeSystem(ABS)............................................................................157

AutomaticTractionControl(A TC)(IfEquipped).................................................162

GOODDRIVINGHABITS.......................................................................................163

WeightRatings.......................................................................................................163

Instruments.............................................................................................................163

ShuttingDowntheEngine.....................................................................................163

GeneralObservation..............................................................................................163

STARTINGTHEVEHICLE.....................................................................................164

GeneralInformation...............................................................................................164

PushButtonStarters...............................................................................................164

AirStarters.............................................................................................................165

EngineWarm-Up...................................................................................................168

EngineIdling..........................................................................................................168

ShuttingDowntheEngine.....................................................................................169

COLDWEA THEROPERA TION.............................................................................171

ColdWeatherStartingTips....................................................................................171

EngineBlockHeaters............................................................................................172

Winterfronts...........................................................................................................173

COUPLINGATRAILER..........................................................................................176

UNCOUPLINGATRAILER....................................................................................178

MOVINGTHEVEHICLE—GENERALINFORMA TION...................................180

Braking...................................................................................................................180

Shifting...................................................................................................................180

EngineTemperature...............................................................................................181

Clutch(IfEquipped)..............................................................................................182

POWERTAKE-OFF(PTO).....................................................................................186

PTOPrecautions....................................................................................................186

PTOClassication.................................................................................................187

Side-MountedPTOLocations...............................................................................187

PTOOperatingProcedures....................................................................................187

TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................188

ShiftingInstructionsforAllisonAutomaticTransmissions..................................188

MACKT306GShiftingInstructions.....................................................................189

MACKTM308ShiftingInstructions.....................................................................190

MACKTM308MShiftingInstructions.................................................................192

MACKTM309ShiftingInstructions.....................................................................194

MACKTM309MShiftingInstructions.................................................................195

MACKT309,T309LandT309LRShiftingInstructions......................................198

MACKT310ShiftingInstructions........................................................................202

MACKT310M,T310MEandT310MLRShiftingInstructions...........................205

MACKT313-T313L-T313LRShiftingInstructions.............................................209

MACKT31321,T313L21andT313LR21ShiftingInstructions..........................213

MACKT318,T318LandT318LRShiftingInstructions......................................217

MACKT31821,T318L21andT318LR21ShiftingInstructions..........................224

PrecautionsWhenDescendingGradesIfVehicleisEquippedwithEaton

AutoShiftGenerationIandII................................................................................230

AXLES.......................................................................................................................231

RearAxlesOtherThanMACK.............................................................................231

MACKRearAxles.................................................................................................231

EngagingthePowerDividerLockout....................................................................233

Mack,EPA2010EmissionsSolution...........................................................................234

DIESELPARTICULA TEFIL TERS(IFEQUIPPED)..............................................234

ExtendedIdlingandAftertreatmentSystemConditioning...................................237

ExhaustAftertreatmentSystem.................................................................................238

SafetyInformation.................................................................................................239

ExhaustAftertreatmentSystemComponentsand................................................240

SelectiveCatalyticReduction(SCR)....................................................................240

DieselExhaustFluid(DEF)...................................................................................243

AftertreatmentDieselParticulateFilter(DPF)......................................................246

AftertreatmentControlModule(ACM).................................................................247

ExhaustAftertreatmentSystem............................................................................248

DriverWarningsandOnBoardDiagnostics(OBD).............................................254

OnBoardDiagnostics(OBD)................................................................................254

InstrumentCluster..................................................................................................255

MalfunctionIndicatorLamp(MIL).......................................................................256

AftertreatmentDEFTankLevel-DriverWarning&Inducement........................257

AftertreatmentDEFQuality-DriverWarning&Inducement..............................258

MisllingDieselorAftertreatmentDEFTanks.....................................................259

SCRTampering-DriverW arning&Inducement.................................................260

WarrantyandMaintenance....................................................................................261

ExhaustAftertreatmentSystemMaintenance........................................................261

EngineMaintenanceIntervals................................................................................261

MAINTENANCEANDLUBRICATION..................................................................262

MAINTENANCEINTRODUCTION.......................................................................262

TURBOCHARGER...................................................................................................263

CLEANINGYOURVEHICLE.................................................................................263

ExteriorWashing...................................................................................................264

CabandHood........................................................................................................266

Chassis...................................................................................................................266

CabInterior............................................................................................................267

Waxing...................................................................................................................267

Polishing................................................................................................................267

WinterW arnings....................................................................................................267

TOWING...................................................................................................................268

TowingwithMACKAir(ALorMAXAIR®40)Suspension(IfEquipped).......270

ENGINEOILLEVELCHECK.................................................................................271

OilChangeIntervals..............................................................................................272

EngineMaintenanceIntervals................................................................................273

PowerSteeringReservoir......................................................................................274

FUELTANK..............................................................................................................275

FuelTankCap........................................................................................................275

FUELING..................................................................................................................275

B5ApprovalForMackUS10CertiedProducts..................................................277

COOLINGSYSTEM.................................................................................................278

CoolantLevelCheck..............................................................................................279

DrainingtheCoolingSystem.................................................................................279

RellingtheCoolingSystem.................................................................................279

ProtectingtheCoolingSystem..............................................................................280

CoolingSystemMaintenance................................................................................282

AccessoryDriveBeltRouting...............................................................................282

HEADLIGHTS..........................................................................................................283

BulbReplacement..................................................................................................283

WHEELS...................................................................................................................286

WheelInspection...................................................................................................286

Tires.......................................................................................................................287

BATTERY..................................................................................................................289

Jump-StartingEngine.............................................................................................290

ELECTRICAL...........................................................................................................292

CircuitBreakerandRelayPanels..........................................................................292

ElectricalGrease....................................................................................................295

CircuitProtectionCharts........................................................................................295

ElectricalAccessoryConnectionPoints................................................................298

METRICCONVERSIONS.........................................................................................300

METRICCONVERSIONS.......................................................................................300

SafetyInformation

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

ITISIMPOR T ANTTHATTHE FOLLOWINGINFORMA TIONBE READ,UNDERSTOODANDALW A YS 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.

CALIFORNIAPROPOSITION65W ARNING

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCalifornia tocausecancer,birthdefectsandotherreproductiveharm.

CALIFORNIAPROPOSITION65W ARNING

Batteryposts,terminalsandotherrelatedaccessoriescontainleadandlead compounds,chemicalknowntotheStateofCaliforniatocausecancerandother reproductiveharm. BatteriesalsocontainotherchemicalsknowntotheStateofCaliforniatocausecancer.

Washhandsafterhandling.

INTRODUCTION1

TOTHEOWNER

InAppreciation

ThankyouforbuyingaMACK®vehicle.Withpropercareandmaintenance, yournewMack®Pinnacle™modelwillhelpyougainacompetitiveedgewith itsfuel-efcientdrivetraincombinations,lowmaintenance,extendedservice intervalsand,eventually,goodresalevalue.

TheMack®Pinnacle™modelisavailableforawiderangeofapplications. Becauseofthisversatility,drivetrainsandcomponentsvaryandoperating instructionsmaydifferfromonemodeltoanother.Whileeveryefforthas beenmadetocoverallcurrentarrangements,donothesitatetoconsultyour MACKdistributorifaquestionarises.Honest,personalserviceisstandard witheveryMACKsale.

CAUTION

MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.

We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack® Pinnacle™model,andthatyouseemanyyearsoftrouble-freedriving.

Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations applicableatthetimeofmanufacture.

2INTRODUCTION

AboutThisHandbook

ThishandbookisreferredtoastheMack®Pinnacle™SeriesOperator’s Handbook.ItcoversallMack®Pinnacle™CHUmodels.Keepthishandbook withthevehicleatalltimestoensurethateachownerand/oroperatorwillhave accesstoallpertinentinformationrelatingtotheandhandlingofthisvehicle.

Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation concerningthedailyuseofthisvehicle.Pleasereaditthoroughly;pay particularattentiontoadvisorylabelsthathavebeenincludedtodrawattention toimportantissuesofoperatorsafetyandoverallperformance.

Informationandillustrationsinthishandbookarebasedonthelatest productionusageatthetimeofprintingandaresubjecttochangewithout priornotice.

Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual. Forfurtherinformation,refertotheMaintenanceandLubricationManual.Other importantinformationcanbefoundintheEmissionControlSystemsforMACK DieselEngineManual.

INTRODUCTION3

THEVEHICLE

BasicConguration

TheMack®Pinnacle™modelfeaturesaconventionallystyled,aerodynamiccab.

VehicleManagementandControlSystem (V-MAC®)

TheV ehicleManagementandControlSystem(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

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

TheVINframestampingislocatedonthebottomrightframerailangeand thetopleftrailange.NotethattheVINlocationmayvaryifre-stampingof theframebecomesnecessary.

TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.

C0028939

C0028940

INTRODUCTION5

C0028941

EngineIdentication

OntheMACKMPengines,theengineserialnumberisstampedontheleft sideoftheengineblock,belowtheinletmanifold.

C0028943

6INTRODUCTION

EngineInformationPlate

IncompliancewithFederalemission requirements,anengineinformationlabel isafxedtoallMackdieselengines.This label,whichislocatedonthecylinderhead coveratthefrontoftheengine,givesbasic engineidenticationinformation(engine

EngineIdenticationLabel—49StateEP AApprovedEnginewithoutCalifonia“CleanIdle”

model,serialnumber,etc.),advertised horespoweratratespeed,inletandexhaust valvelashsetting.TheEnginefamily “A VPTH12.8S01”canbeusedtoidentify theemissionstandardunderwhichthe enginewascertied.

W2040455

W2040456

EngineIdenticationLabel—50StateEPAApprovedEnginewithCalifonia“CleanIdle”

INTRODUCTION7

CAUTION

Tomaintaincompliancewithemission regulations,enginesettingsshouldnot bechangedfromthosespeciedonthe engineinformationlabel.

Note:BoththeU.S.EPAandCalifornia AirResourcesBoardrequiresthateach enginebeidentiedwiththeproperengine

labelasshownabove.Shouldthisengine labelbedefaced,destroyed,orremoved fromthevalvecover,itmustbereplaced immediately.Toorderareplacement label,pleasecontactSpecications orPartsInterpretationsdepartmentat 1–800–888–9878,Option2,whowill assistyouinobtainingthecorrectlabelfor yourengine.

CleanIdleEngines

TheCaliforniaAirResourcesBoard(ARB)requiresthat2008andlatermodel yearvehiclesbeequippedwithengineshavingtamper-resistantsoftware whichlimitsthetimeatwhichtheenginecanidleatspeedsabovelowidle (550–700rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idle timewillbelimitedtoveminutes,afterwhichtheenginewillrevertbacktolow idle.VehiclesequippedwithaCleanIdleengineareidentiedbyalabelwhich isafxedtotheleftfrontcornerofthehoodonconventionalmodels(CHU).

CleanIdleEngineLabel

W2056289

8INTRODUCTION

TransmissionIdentication

TheMACKT300Seriestransmissionserialnumberislocatedontherear leftsideofthemaincase.

C0028947

TheAllisonRDSandHStransmissionidenticationplateislocatedonthe rearrightsideofthemaincase,nearthelowerend.

C0028948

AllEaton®Fuller®transmissionidenticationplatesarelocatedonthe frontleftsideofthemaincase.

C0028949

TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside ofthehousing.

INTRODUCTION9

C0028950

TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe axlehousingtowardthecarrier.

C0028951

TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft sideoftheforwardcarrier,andthetopoftherearcarrier.

C0028952

TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof therearaxlehousing,nexttothecarrier .

10INTRODUCTION

C0028953

TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof theforwardcarrier,andthetopoftherearcarrier.

C0028954

INTRODUCTION11

WARRANTYINFORMATION

ThischassisisequippedwithaUS2010emissioncompliantenginewithan engineexhaustaftertreatmentsystem(DieselParticulateFilter)andselective catalyticreduction(SCR)system.UseofUltraLowSulfurDiesel(ULSD)fuel andEO-OPremiumPlus(orVDS-4)specicationhighperformancediesel engineoilisrequiredinthisvehicle.

Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand aftertreatmentsystemwarranty.

AirBrakeSystem

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

Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.

Tractorairsystemsaredesignedforasatractoronly,andtruckairsystems aredesignedtobeoperatedasatruckonly.Ifatractorisgoingtobe convertedforasatruck,theairbrakesystemmustbereconguredtothat ofatruck.Conversely,ifatruckisgoingtobeconvertedforasatractor,the airbrakesystemmustbereconguredtothatofatractor.Consultyourlocal MACKdistributorforadditionalinformation.

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

Forcompletewarrantyinformation,refertothePedigreedProtectionPlan providedwitheachvehicle.

12INTRODUCTION

ENGINEGASEOUSEMISSIONCONTROL SYSTEMS

WARRANTYMAINTENANCE

Note:Foremissioncontrolsystems informationonenginesotherthanMACK, refertotheenginevendor’spublication

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 ControlSystemsWarranty:

•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 ANDREPRESENT A TIONSORCONDITIONS,STA TUTORYOR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA PARTICULARPURPOSE.

INTRODUCTION13

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandV ehicleWireharness(

repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRV alveandEGRValveControl

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

•DischargeRecirculationV alve

(DRV)(HeatMode)

•DischargeRecirculationV alve

(DRV)Solenoid

•EngineTurbochargerCompressor

BypassActuator(HeatMode)

•EngineTurbochargerCompressor

BypassActuatorSolenoid

•EngineExhaustGasT emperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFCombustion

AirControlValve

•AftertreatmentDPFCombustion

AirValve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasT emperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

14INTRODUCTION

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AA T)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFTank

Heater/Sender

•AftertreatmentDEFTankHeater

•AftertreatmentDEFT ankHeater

Valve

•AftertreatmentDEFTank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

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

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

ENGINEGASEOUSEMISSIONSCONTROL SYSTEMWARRANTY

INTRODUCTION15

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.

16INTRODUCTION

FEDERALEMISSIONREQUIREMENTS

Thissectioncoverstherequirementofthe UnitedStatesCleanAirActwhichstates: “Themanufacturershallfurnishwith eachnewmotorvehicleormotorvehicle enginesuchwritteninstructionsforthe maintenanceanduseofthevehicleor enginebytheultimatepurchaserasmay

TAMPERINGWITHGASEOUSEMISSIONCONTROLSYSTEMS PROHIBITED

TheFederalCleanAirActprohibitsthe removalorrenderinginoperativeofany deviceorelementofdesigninstalledonor inamotorvehicleormotorvehicleengine incompliancewithFederalEmission Regulationsby:

1Anypersonpriortoitssaleanddelivery

totheultimatepurchaser,or

2Anymanufacturerordistributorafter

itssaleanddeliverytotheultimate purchaser,or

3Anypersonengagedinthebusinessof

repairing,servicing,selling,leasing,or

bereasonableandnecessarytoassurethe properfunctioningofemissioncontrol devicesandsystems.”Thissectionalso coverstherequirementsoftheemissions regulationspromulgatedundertheMotor VehicleSafetyActinCanada.

4Anypersonwhooperatesaeetof

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

tradingmotorvehiclesormotorvehicle enginesfollowingitssaleanddelivery totheultimatepurchaser,or

motorvehiclesfollowingitssaleand deliverytotheultimatepurchaser.

EMISSIONCONTROLSYSTEMSWARRANTY— CALIFORNIA

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

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

MANUFACTURER’SWARRANTY COVERAGE:

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

OWNER’SWARRANTYRESPONSIBILITIES:

INTRODUCTION17

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 SystemsWarranty:

•Malfunctionscausedbymisuse,

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

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

18INTRODUCTION

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheCaliforniacodeofregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandV ehicleWireharness(

repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRV alveandEGRValveControl

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

•EngineExhaustGasT emperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFAirShutoff

Valve

•AftertreatmentDPFCombustion

AirValve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

INTRODUCTION19

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasT emperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AA T)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFTank

Heater/Sender

•AftertreatmentDEFTankHeater

•AftertreatmentDEFT ankHeater

Valve

•AftertreatmentDEFTank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

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

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

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