TITAN by MACKTM (TD700 Series)
21394652 April 2010
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Foreword
This manual contains information concerning the operation and function of the Mack Link System. The information in this manual appliestovehiclesbuilt April 2010 and later. Please keep this manual in the vehicle at all times.
Note: Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle. However, key components addressed in this document are represented as accurately as possible.
The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America should be informed immediately if you believe that the vehicle has a defect that could cause a crash, injury or death.
Contact NHTSA by calling the Auto Safety Hotline at 1 (888) 327-4236, by writing to NHTSA, U.S. Department of Transportation, Washington, DC 20590, by TTY at 1 (800) 424-9153, or visit their website at www.nhtsa.dot.gov.
Mack Trucks Inc.
Greensboro, NC USA
Order number: PV776-21394652
©2010Mack Truck Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Mack Trucks Inc.
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Contents |
|
INTRODUCTION............................................................................................................ |
1 |
TO THE OWNER.......................................................................................................... |
1 |
In Appreciation.......................................................................................................... |
1 |
About This Handbook................................................................................................ |
2 |
THE VEHICLE.............................................................................................................. |
3 |
Basic Configuration ................................................................................................... |
3 |
Vehicle Management and Control System (V-MAC®)............................................. |
3 |
COMPONENT IDENTIFICATION.............................................................................. |
4 |
VIN Locations............................................................................................................ |
4 |
Engine Identification.................................................................................................. |
5 |
Engine Information Plate........................................................................................... |
6 |
Clean Idle Engines..................................................................................................... |
7 |
Transmission Identification........................................................................................ |
8 |
WARRANTY INFORMATION.................................................................................. |
11 |
Air Brake System..................................................................................................... |
11 |
ENGINE GASEOUS EMISSION CONTROL SYSTEMS .................................... |
11 |
Emissions Control System Warranty....................................................................... |
13 |
ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY............. |
15 |
FEDERAL EMISSION REQUIREMENTS............................................................ |
16 |
EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA.................. |
16 |
Emissions Control System Warranty....................................................................... |
18 |
SERVICE LITERATURE............................................................................................ |
22 |
MACK Class 8 –Components Service Manual ....................................................... |
22 |
Class 8 – Custom Collated Service Manual on CD................................................. |
22 |
CUSTOMER SERVICE .............................................................................................. |
23 |
Call 1-800-866-1177 for MACK OneCall™........................................................... |
23 |
Questions and Complaints....................................................................................... |
23 |
Addresses................................................................................................................. |
24 |
Additional Assistance.............................................................................................. |
25 |
REPORTING SAFETY DEFECTS............................................................................. |
26 |
United States............................................................................................................ |
26 |
Canada...................................................................................................................... |
26 |
Mexico..................................................................................................................... |
26 |
EVENT DATA RECORDING DEVICES................................................................... |
27 |
................................................................................................................................. |
27 |
SAFETY INFORMATION........................................................................................... |
28 |
SAFETY STATEMENT .............................................................................................. |
28 |
CERTIFICATION LABELS........................................................................................ |
30 |
Safety Certification Label........................................................................................ |
30 |
ADVISORY LABELS................................................................................................. |
32 |
Advisory Label Locations (On Vehicle).................................................................. |
33 |
TRUCK-TRACTOR CONSPICUITY......................................................................... |
43 |
CAB ENTRY/EXIT..................................................................................................... |
44 |
Three-Limb Contact................................................................................................. |
44 |
Driver Side............................................................................................................... |
46 |
Passenger Side ......................................................................................................... |
48 |
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Deck Plate Access.................................................................................................... |
50 |
SAFETY TIPS FOR COLD WEATHER OPERATION............................................. |
52 |
Driver Visibility....................................................................................................... |
52 |
Cab Door Seals and Key Locks............................................................................... |
53 |
Outside Mirror Heater.............................................................................................. |
53 |
Air Horn Snow Shield.............................................................................................. |
54 |
Emergency Reflector Kit.......................................................................................... |
54 |
Fire Extinguisher (Optional).................................................................................... |
54 |
INSTRUMENTS AND CONTROLS........................................................................... |
55 |
CAB INTERIOR.......................................................................................................... |
55 |
INSTRUMENT PANEL.............................................................................................. |
56 |
Tell-Tales.................................................................................................................. |
56 |
Panel Arrangement................................................................................................... |
57 |
INSTRUMENT PANEL GAUGE LAYOUT.............................................................. |
58 |
Panel A..................................................................................................................... |
60 |
Panel B..................................................................................................................... |
61 |
Panel C..................................................................................................................... |
63 |
Panel D..................................................................................................................... |
64 |
Function of Optional Switches................................................................................. |
77 |
CAB CLIMATE CONTROL....................................................................................... |
84 |
LIGHT CONTROL PANEL........................................................................................ |
86 |
LOWER CONSOLE PANEL...................................................................................... |
87 |
STEERING COLUMN................................................................................................ |
88 |
Combination Starter and Electrical Switch.............................................................. |
88 |
Steering Wheel Adjustment..................................................................................... |
88 |
Turn Signal Lever.................................................................................................... |
89 |
Stalk Switch (If Equipped, Co-Pilot® Only)........................................................... |
90 |
FLOOR PEDALS........................................................................................................ |
92 |
MISCELLANEOUS CONTROLS.............................................................................. |
93 |
Dome Light.............................................................................................................. |
93 |
Air Horn................................................................................................................... |
94 |
Fresh Air Vent.......................................................................................................... |
94 |
Cab Air Filter........................................................................................................... |
95 |
Microphone.............................................................................................................. |
95 |
Accessory Power Outlets......................................................................................... |
96 |
OPERATION.................................................................................................................. |
98 |
PRE-TRIP INSPECTION AND DAILY MAINTENANCE....................................... |
98 |
Pre-Trip Inspection Quick List ................................................................................ |
99 |
New Vehicle Break-In............................................................................................ |
110 |
WINDSHIELD WASHER RESERVOIR.................................................................. |
112 |
HOOD OPERATION................................................................................................. |
113 |
Opening the Hood.................................................................................................. |
113 |
Closing the Hood................................................................................................... |
114 |
Locking the Hood .................................................................................................. |
115 |
HOSE TENDERS...................................................................................................... |
117 |
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DOORS...................................................................................................................... |
118 |
Power Door Panel (Optional)................................................................................. |
118 |
Opening the Cab Door........................................................................................... |
119 |
Locking the Cab Door............................................................................................ |
120 |
Power Window Regulators.................................................................................... |
120 |
REMOTE KEYLESS ENTRY — (OPTIONAL)...................................................... |
121 |
Transmitter Operations .......................................................................................... |
122 |
Battery Replacement.............................................................................................. |
123 |
SEAT BELTS............................................................................................................. |
126 |
Seat Belt Operation................................................................................................ |
126 |
Fastening Seat Belt ................................................................................................ |
126 |
Adjustable D-Ring Shoulder Belts (if equipped)................................................... |
128 |
Komfort® Latch System........................................................................................ |
129 |
SEAT ADJUSTMENT AND RECLINE (IF EQUIPPED)........................................ |
131 |
MIRROR BREAKAWAY STRUT............................................................................ |
132 |
MACK ENGINE INFORMATION........................................................................... |
133 |
Precautions and Warnings...................................................................................... |
133 |
Engine Model Designations................................................................................... |
135 |
TIRE PRESSURE CONTROL SYSTEM (IF EQUIPPED)...................................... |
136 |
Operating the Dana Tire Pressure Control System................................................ |
137 |
Tire Changing Procedure....................................................................................... |
142 |
CRUISE CONTROL OPERATION.......................................................................... |
144 |
Speed Control Switches......................................................................................... |
144 |
Setting Cruise Control ........................................................................................... |
144 |
Disengaging Cruise Control................................................................................... |
145 |
MACK POWERLEASH™ ENGINE BRAKE (IF EQUIPPED).............................. |
146 |
Engine Brake Switch.............................................................................................. |
146 |
How the Engine Brake is Activated....................................................................... |
147 |
Cruise Control with the MACK PowerLeash™ Engine Brake............................. |
148 |
ON THE ROAD WITH THE MACK POWERLEASH™ ENGINE BRAKE......... |
149 |
Over Flat Terrain.................................................................................................... |
150 |
Descending a Grade............................................................................................... |
151 |
On Slippery Road Surfaces.................................................................................... |
153 |
BRAKE OPERATION............................................................................................... |
155 |
Air Brake System................................................................................................... |
155 |
Automatic Slack Adjusters .................................................................................... |
156 |
Parking Brake System............................................................................................ |
156 |
Parking Brake Operation........................................................................................ |
157 |
Parking................................................................................................................... |
157 |
Anti-Lock Brake System (ABS)............................................................................ |
157 |
Automatic Traction Control (ATC) (If Equipped)................................................. |
161 |
GOOD DRIVING HABITS....................................................................................... |
163 |
Weight Ratings....................................................................................................... |
163 |
Instruments............................................................................................................. |
163 |
Shutting Down the Engine..................................................................................... |
163 |
General Observation.............................................................................................. |
163 |
STARTING THE VEHICLE ..................................................................................... |
164 |
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General Information............................................................................................... |
164 |
Push Button Starters............................................................................................... |
164 |
Air Starters............................................................................................................. |
165 |
Engine Warm-Up................................................................................................... |
168 |
Engine Idling.......................................................................................................... |
168 |
Shutting Down the Engine..................................................................................... |
169 |
COLD WEATHER OPERATION............................................................................. |
171 |
Cold Weather Starting Tips.................................................................................... |
171 |
Engine Block Heaters ............................................................................................ |
172 |
Winterfronts........................................................................................................... |
173 |
COUPLING A TRAILER.......................................................................................... |
175 |
UNCOUPLING A TRAILER.................................................................................... |
177 |
MOVING THE VEHICLE — GENERAL INFORMATION................................... |
179 |
Braking................................................................................................................... |
179 |
Shifting................................................................................................................... |
179 |
Engine Temperature............................................................................................... |
180 |
Clutch (If Equipped).............................................................................................. |
180 |
POWER TAKE-OFF (PTO) OPERATION............................................................... |
185 |
PTO Precautions .................................................................................................... |
185 |
PTO Classification................................................................................................. |
186 |
Side-Mounted PTO Locations ............................................................................... |
186 |
PTO Operating Procedures.................................................................................... |
186 |
TRANSMISSION SHIFTING INSTRUCTIONS..................................................... |
187 |
MACK T310 Shifting Instructions........................................................................ |
188 |
MACK T310ME21 Shifting Instructions.............................................................. |
191 |
MACK T31321 and T313LR21 Shifting Instructions........................................... |
194 |
MACK T31821 and T318LR21 Shifting Instructions........................................... |
198 |
AXLES....................................................................................................................... |
204 |
Rear Axles Other Than MACK............................................................................. |
204 |
MACK Rear Axles................................................................................................. |
204 |
Engaging the Power Divider Lockout.................................................................... |
205 |
Extended Idling and Aftertreatment System Conditioning ....................................... |
207 |
Mack, EPA2010 Emissions Solution........................................................................... |
208 |
DIESEL PARTICULATE FILTERS (IF EQUIPPED) .............................................. |
208 |
Extended Idling and Aftertreatment System Conditioning ................................... |
211 |
Exhaust Aftertreatment System................................................................................. |
212 |
Safety Information................................................................................................. |
213 |
Exhaust Aftertreatment System Components and ................................................ |
214 |
Selective Catalytic Reduction (SCR) .................................................................... |
214 |
Diesel Exhaust Fluid (DEF)................................................................................... |
217 |
Aftertreatment Diesel Particulate Filter (DPF)...................................................... |
220 |
Aftertreatment Control Module (ACM)................................................................. |
221 |
Exhaust Aftertreatment System ............................................................................ |
222 |
Driver Warnings and On Board Diagnostics (OBD) ............................................. |
227 |
On Board Diagnostics (OBD)................................................................................ |
227 |
Instrument Cluster.................................................................................................. |
228 |
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Malfunction Indicator Lamp (MIL)....................................................................... |
229 |
Aftertreatment DEF Tank Level - Driver Warning & Inducement........................ |
230 |
Aftertreatment DEF Quality - Driver Warning & Inducement.............................. |
231 |
Misfilling Diesel or Aftertreatment DEF Tanks..................................................... |
232 |
SCR Tampering - Driver Warning & Inducement................................................. |
233 |
Warranty and Maintenance.................................................................................... |
234 |
Exhaust Aftertreatment System Maintenance........................................................ |
234 |
Engine Maintenance Intervals................................................................................ |
234 |
MAINTENANCE AND LUBRICATION.................................................................. |
235 |
MAINTENANCE INTRODUCTION....................................................................... |
235 |
TURBOCHARGER................................................................................................... |
236 |
CLEANING YOUR VEHICLE................................................................................. |
237 |
Exterior Washing ................................................................................................... |
237 |
Cab and Hood ........................................................................................................ |
239 |
Chassis................................................................................................................... |
239 |
Cab Interior............................................................................................................ |
240 |
Waxing................................................................................................................... |
240 |
Polishing ................................................................................................................ |
240 |
Winter Warnings.................................................................................................... |
240 |
TOWING ................................................................................................................... |
241 |
AIR CLEANER..................................................................................................... |
242 |
ENGINE OIL LEVEL CHECK................................................................................. |
243 |
Power Steering Reservoir ...................................................................................... |
244 |
FUEL TANK.............................................................................................................. |
246 |
Fuel Tank Cap........................................................................................................ |
246 |
FUELING .................................................................................................................. |
247 |
BioDiesel................................................................................................................ |
248 |
B20 Approval For Mack EPA 07 Certified Products............................................. |
248 |
COOLING SYSTEM................................................................................................. |
249 |
Coolant Level Check.............................................................................................. |
249 |
Draining the Cooling System................................................................................. |
250 |
Refilling the Cooling System................................................................................. |
251 |
Protecting the Cooling System .............................................................................. |
251 |
Cooling System Maintenance................................................................................ |
252 |
Accessory Drive Belt Routing............................................................................... |
253 |
HEADLIGHTS.......................................................................................................... |
254 |
Bulb Replacement.................................................................................................. |
254 |
LICENSE PLATE MOUNTING............................................................................... |
254 |
WHEELS................................................................................................................... |
255 |
Wheel Inspection ................................................................................................... |
255 |
Tires ....................................................................................................................... |
256 |
BATTERY.................................................................................................................. |
259 |
Jump-Starting Engine............................................................................................. |
259 |
ELECTRICAL........................................................................................................... |
261 |
Circuit Breaker and Relay Panels.......................................................................... |
261 |
Electrical Grease.................................................................................................... |
263 |
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Electrical Accessory Connection Points................................................................ |
267 |
METRIC CONVERSIONS......................................................................................... |
275 |
METRIC CONVERSIONS ....................................................................................... |
275 |
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Safety Information
IMPORTANT: Before driving this vehicle, be certain that you have read and that you fully understand each and every step of the driving and handling information in this manual. Be certain that you fully understand and follow all safety warnings.
IT IS IMPORTANT THAT THE FOLLOWING INFORMATION BE READ, UNDERSTOOD AND ALWAYS FOLLOWED.
The following types of advisories are used throughout this manual:
DANGER
Danger indicates an unsafe practice that could result in serious personal injury or death. A danger advisory banner is in white type on a black background with a black border.
WARNING
Warning indicates an unsafe practice that could result in personal injury. A warning advisory banner is in black typeona gray backgroundwitha black border.
CAUTION
Cautionindicatesanunsafepracticethat could result in damage to the product. A caution advisory is in black type on a white background with a black border.
Note: Noteindicatesaprocedure,practice, orconditionthatmustbefollowedinorder for the vehicle or component to function in the manner intended.
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INTRODUCTION 1
TO THE OWNER
In Appreciation
Thank you for buying a MACK® vehicle. With proper care and maintenance, your newMack®TD700modelwillhelpyougainacompetitiveedgewithitsfuel-efficient drivetrain combinations, low maintenance, extended service intervals and, eventually, good resale value.
The Mack® TD700 model is available for a wide range of applications. Because of this versatility, drivetrains and components vary and operating instructions may differ from one model to another. While every effort has been made to cover all current arrangements, do not hesitate to consult your MACK distributor if a question arises. Honest, personal service is standard with every MACK sale.
CAUTION
Mack Trucks, Inc. would like to point out the important role that the driver plays in thelifeofthevehicle. Onlytrainedandinformeddriversshouldoperatethisvehicle.
We, at Mack Trucks, Inc., hope that you will be happy with your new Mack® TD700 model, and that you see many years of trouble-free driving.
This vehicle was built to conform to all federal standards and regulations applicable at the time of manufacture.
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2 INTRODUCTION
About This Handbook
This handbook is referred to as the Mack® TD700 Series Operator’s Handbook. It covers all Mack® TD700 models. Its identification number is 213946521. Keep this handbook with the vehicle at all times to ensure that each owner and/or operator will have access to all pertinent information relating to the operation and handling of this vehicle.
This handbook was prepared to provide the driver with all relevant information concerning the daily operation of this vehicle. Please read it thoroughly; pay particular attention to advisory labels that have been included to draw attention to important issues of operator safety and overall performance.
Information and illustrations in this handbook are based on the latest production usage at the time of printing and are subject to change without prior notice.
Note: Basic maintenance and lubrication procedures are found in this manual beginning with “MAINTENANCE INTRODUCTION”, page 235. For further information, refer to the Maintenance and Lubrication Manual (21394653). Other important information can be found in the Emission Control Systems for MACK Diesel Engine Manual.
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INTRODUCTION 3
THE VEHICLE
Basic Configuration
The Mack® TD700 model features a conventionally styled, aerodynamic cab.
Vehicle Management and Control System
(V-MAC®)
The Vehicle Management and Control System (V-MAC) is an electronic control system that manages engine and vehicle functions. In addition, the DataMax™ portion of V-MAC monitors and stores a variety of information (i.e., maintenance schedules, overspeed logs, fault tables, trip summaries).
For a complete description of the V-MAC IV system, refer to the applicable V-MAC® Operator’s Guide, which is supplied with the vehicle.
Additional information concerning service, diagnostics, programming and vendor equipment interface application is available from the Mack Trucks, Inc. Service Publications Department. Contact your local MACK dealer for details.
WARNING
Never cut into the V-MAC system wire harness to power additional equipment. If such equipment is to be installed, contact your MACK dealer for assistance.
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4 INTRODUCTION
COMPONENT IDENTIFICATION
Locate the following serial numbers and write them in the boxes provided next to each illustration.
VIN Locations
The Vehicle Identification Number (VIN) is displayed in two locations (a frame rail stamping and a label). The 17-digit VIN must be identical in both locations.
The VIN frame stamping is located on the right outside frame rail and the left inside frame rail.
C0029937
The VIN label is located on the inside door frame below the driver seat.
C0028941
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INTRODUCTION 5
Engine Identification
On the MACK MP engines, the engine serial number is stamped on the left side of the engine block, below the inlet manifold.
C0028943
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6 INTRODUCTION
Engine Information Plate
In compliance with Federal and California emission requirements, an engine information label is affixed to all MACK diesel engines. This label, which is located on the cylinder head cover at the front of the engine, gives basic engine identification information (engine model, serial number, etc.), advertised horsepower at rated speed, emissions regulations to which the engine conforms and inlet and exhaust valve lash settings. Examples of the 49 state EPA approved, and 50 state EPA and California approved engine identification labels are given below.
W2040455
Engine Identification Label - 49 State EPA Approved Engine without California "Clean Idle"
W2040456
Engine Identification Label - 50 State EPA Approved Engine with California "Clean Idle"
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INTRODUCTION 7
Clean Idle Engines
The California Air Resources Board (ARB) requires that 2008 model year vehicles be equipped with engines having tamper-resistant software which limits the time at which the engine can idle at speeds above low idle (550–700 rpm). At speeds above low idle, and without a PTO engaged, idle time will be limited to five minutes, after which the engine will revert back to low idle. Vehicles equipped with a Clean Idle engine are identified by a label which is affixed to the left front corner of the hood on conventional models ( TD700).
W2056289
Clean Idle Engine Label
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8 INTRODUCTION
Transmission Identification
The MACK T300 Series transmission serial number is located on the rear left side of the main case.
C0028947
All Eaton® Fuller® transmission identification plates are located on the front left side of the main case.
C0028949
The MACK carrier assembly serial number is located on the front right side of the housing.
C0028950
The Eaton® Spicer® rear axle serial number is located on the rear of the axle housing toward the carrier.
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INTRODUCTION 9
C0028951
The Eaton® Spicer® carrier assembly serial number is located on the left side of the forward carrier, and the top of the rear carrier.
C0028952
The MERITOR rear axle identification tag is located on the left or right rear of the rear axle housing, next to the carrier.
C0028953
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10 INTRODUCTION
The MERITOR carrier assembly serial number is located on the left side of the forward carrier, and the top of the rear carrier.
C0028954
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INTRODUCTION 11
WARRANTY INFORMATION
This chassis is equipped with a US10 emission compliant engine and an exhaust aftertreatment system (Diesel Particulate Filter). Use of Ultra Low Sulfur Diesel (ULSD) fuel and EO-O Premium Plus (or VDS-4) specification high performance diesel engine oil is required in this vehicle.
Note: Use of improper or unapproved fuel or engine oil will void the engine and aftertreatment system (Diesel Particulate Filter) warranty. 2007 emission engines REQUIRE the use of EO-O Premium Plus (or VDS-4) specification high performance diesel engine oil and Ultra Low Sulfur Diesel (ULSD) fuel.
Air Brake System
The MACK Standard Vehicle Warranty applies to the air brake system, as set forth in the Warranty, but only if the air brake system has not been subjected to unauthorized additions, deletions or modifications. If any such unauthorized additions, deletions or modifications are performed, Mack Trucks, Inc. disclaims any and all liability for any loss or damage arising out of a malfunction of the air brake system.
The air brake system was designed and built to conform to all applicable federal motor vehicle safety standards in effect at the time of manufacture.
Tractor air systems are designed for operation as a tractor only, and truck air systems are designed to be operated as a truck only. If a tractor is going to be converted for operation as a truck, the air brake system must be reconfigured to that of a truck. Conversely, if a truck is going to be converted for operation as a tractor, the air brake system must be reconfigured to that of a tractor.
Consult your local MACK distributor for additional information.
If any unauthorized additions, deletions or modifications are made to any portion of the air brake system which is required by Federal Motor Vehicle Safety Standards, Mack Trucks, Inc. makes no representation as to conformity with the Standards.
For complete warranty information, refer to the Pedigreed Protection Plan provided with each vehicle.
ENGINE GASEOUS EMISSION CONTROL SYSTEMS
WARRANTY MAINTENANCE
Note: For emission control systems information on engines other than MACK,
refer to the enginehttps://wwwvendor’ publica.truckion -manuals.net/
12 INTRODUCTION
ENGINE GASEOUS EMISSION CONTROL SYSTEMS WARRANTY
Mack Trucks, Inc. warrants the Emission Control Systems on each new Mack diesel engine in a new Mack Truck to comply with all United States Federal and Canadian emissions regulations applicable at the time of manufacture of the engine, and to be free from defects in material and workmanship under normal use and service up to 60 months, or 160934 km (100,000 miles), which ever occurs first, provided that all Mack Trucks, Inc. maintenance requirements are followed as described in this manual. All warranty periods are calculated from the date-in-service of the new vehicle.
The repair or replacement of defective parts will be made without charge for the cost of parts and if repairs are made at an authorized Mack Trucks, Inc. dealership, there will be no charge for labor. Mack Trucks, Inc.’s obligation under this warranty is limited to the repair or replacement, at Mack Trucks, Inc.’s option, of any part(s) of the Emission Control Systems of such engine and/or vehicle found to be defective upon examination by Mack Trucks, Inc. and provided that such part(s) were returned to MackTrucks,Inc. oritsnearestauthorized Dealer within a reasonable period of time.
Qualifications and Limitations:
Note: Not covered by the Emissions Control Systems Warranty:
•Malfunctions caused by misuse, improper adjustments, modification, alteration, tampering, disconnection, improper or inadequate maintenance and use of improper diesel fuel or DEF.
•Damage resulting from accident, acts of nature or other events beyond the control of Mack Trucks, Inc.
•
•
Inconvenience, loss of use of the vehicle, commercial loss of any kind including, but not limited to, consequential or incidental damages
Any vehicle in which the odometer has been altered or damaged so that mileage cannot be readily determined.
THISWARRANTYISEXPRESSLYINLIEUOFALLOTHERWARRANTIES AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
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INTRODUCTION 13
Emissions Control System Warranty
The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal code of emission regulations.
1Turbocharger Assembly
•VGT Actuator
2Charge Air Cooler
•CAC Pipes (Air inlet to/from CAC)
•CAC Hoses
3Engine Control Module (ECM)
•Aftertreatment Fuel Pressure Sensor
•Discharge Recirculation Valve (DRV) (Heat Mode)
•Discharge Recirculation Valve (DRV) Solenoid
•Engine Turbocharger Compressor Bypass Actuator (Heat Mode)
4Injectors
5Engine and Vehicle Wire harness ( repair to circuits related to Emissions Warrantable Components )
•Engine Turbocharger Compressor Bypass Actuator Solenoid
•Engine Exhaust Gas Temperature (EGT) Sensor
6Exhaust Gas Recirculation (EGR) Mixer
7EGR Cooler
8EGR Valve and EGR Valve Control
9EGR Pipes - Engine Exhaust Manifold to EGR Cooler
10EGR Pipes - EGR Cooler to Inlet Manifold
11Crankcase Breather
12Crankcase Separator
13Crankcase Tubing and Hoses before Separator
14Aftertreatment Wiring Harness
•Aftertreatment DPF Intake Temperature Sensor
•Aftertreatment DPF Outlet Temperature Sensor
•Aftertreatment DPF Differential Pressure Sensor
•Aftertreament Doser Air Supply Regulator (if applicable), Supply Lines, and Fittings
B.Thermal Regeneration Unit (TRU)
•Aftertreatment DPF Combustion Air Control Valve
•Aftertreatment DPF Combustion Air Valve
15 AftertreatmentControlModule(ACM) |
• |
Aftertreatment DPF Atomization |
16 Aftertreatment Diesel Particulate Filter |
|
Module |
(DPF) Assembly |
• Aftertreatment DPF Ignition Coil |
|
A. Aftertreatment DPF Assembly |
• Aftertreatment DPF Fuel Control |
|
with Aftertreatment Diesel Oxidation |
• |
Valve |
Catalyst (DOC) |
Aftertreatment DPF Ignition |
|
• Aftertreatment Doser |
• |
Electrode |
• Diffuser Pipe (Aftertreatment Fuel |
Nozzle |
|
Doser Mounting) |
• Engine Exhaust Gas Temperature |
|
• Fuel lines to Aftertreatment Fuel |
• |
(EGT) Sensor |
Doser |
Aftertreatment DPF Intake |
|
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||
• Aftertreatment Fuel Shutoff Valve |
|
Temperature Sensor |
14 INTRODUCTION
•Aftertreatment DPF Outlet Temperature Sensor
•Aftertreatment DPF Spark Assist Flame Temperature Sensor
•Aftertreatment DPF Differential Pressure Sensor
17Sensors:
•Crankshaft Position (CKP)
•Camshaft Position (CMP)
•Engine Coolant Temperature (ECT)
•Intake Manifold Air Temperature
•Intake Manifold Pressure (IMP)
•EGR Temperature
•Aftertreatment Outlet NOx
•Aftertreatment Intake NOx
•EGR Differential Pressure
•Ambient Air Temperature (AAT)
18SCR
•Aftertreatment Selective Catalytic Reduction (SCR) Catalyst
•Aftertreatment Diesel Exhaust Fluid (DEF) Pump
•Aftertreatment DEF Dosing Absolute Pressure Sensor
•Aftertreatment DEF Return Valve
•Aftertreatment DEF Dosing Valve
•Aftertreatment DEF Tank
•Aftertreatment DEF Tank Heater/Sender
•Aftertreatment DEF Tank Heater
•Aftertreatment DEF Tank Heater Valve
•Aftertreatment DEF Tank Temperature Sensor
•Aftertreatment DEF Level Sensor
•Aftertreatment DEF Heated Lines
19.Instrument Cluster (Repair of microprocessor , OBD MIL, Real Time Clock, Aftertreatment DEF Tank Gauge and, Aftertreatment DEF Tank Low Level Indicator)
20.Exhaust Gas Piping (from Turbocharger to Aftertreatment System )
21.Data Link Connector (DLC)
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INTRODUCTION 15
ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY
The emission warranty for the diesel particulate filter (DPF) and SCR System covers defects in workmanship only. Normal maintenance, such as cleaning ash from the filter at regular maintenance intervals and cleaning the aftertreatment fuel injector on Diesel oxidation catalyst (DOC) DPF systems, is not covered by the emission warranty. With the Thermal regenerator DPF system, cleaning the ignition electrodes and fuel injection nozzleattheregularmaintenanceintervals
is considered normal maintenance and not covered by the emission warranty.
Note: In response to customer requests, MackTrucks,Inc. maybuildvehicleswith engines supplied by other manufacturers. In these cases, each engine manufacturer through its service organization, is responsible for emission control systems warranty on all parts of the engine assembly, as furnished.
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16 INTRODUCTION
FEDERAL EMISSION REQUIREMENTS
This section covers the requirement of the United States Clean Air Act which states: “The manufacturer shall furnish with each new motor vehicle or motor vehicle engine such written instructions for the maintenance and use of the vehicle or engine by the ultimate purchaser as may
be reasonable and necessary to assure the proper functioning of emission control devices and systems. ”This section also covers the requirements of the emissions regulations promulgated under the Motor Vehicle Safety Act in Canada.
TAMPERING WITH GASEOUS EMISSION CONTROL SYSTEMS PROHIBITED
The Federal Clean Air Act prohibits the removal or rendering inoperative of any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with Federal Emission Regulations by:
1Anypersonpriortoitssaleanddelivery to the ultimate purchaser, or
2Any manufacturer or distributor after its sale and delivery to the ultimate purchaser, or
3Any person engaged in the business of repairing, servicing, selling, leasing, or
tradingmotorvehiclesormotorvehicle engines following its sale and delivery to the ultimate purchaser, or
4Any person who operates a fleet of motor vehicles following its sale and delivery to the ultimate purchaser.
Note: For specifics of the prohibited vehicle/engine modifications refer to the Mack Trucks, Inc. Body Builders documentation .
EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA
The California Air Resources Board and Mack Trucks, Inc. are pleased to explain the California emission control system warranty on your new motor vehicle engine. In California, new motor vehicle engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Mack Trucks, Inc. must warrant the emission control system onyourenginefortheperiodoftimelisted below provided there has been no abuse, neglect, or improper maintenance of your engine.
Your emission control system may include parts such as the fuel-injection
system, turbocharger assembly, electronic control module and other emission-related assemblies.
Where a warrantable condition exists, Mack Trucks, Inc. will repair your engine at no cost to you including diagnosis, parts, and labor.
MANUFACTURER’S WARRANTY COVERAGE:
If an emission-related part of your engine is defective, the part will be repaired or replaced by Mack Trucks, Inc. This is your emission control system DEFECTS WARRANTY.
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INTRODUCTION 17
OWNER’S WARRANTY RESPONSIBILITIES:
As the motor vehicle engine owner, you are responsible for the performance of the required maintenance listed in this manual. Mack Trucks, Inc. recommends that you retain all receipts covering maintenance of your vehicle, but Mack Trucks, Inc. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance listed in other manuals which were supplied with your vehicle.
You are responsible for presenting your motor vehicle engine to a MACK dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the motor vehicle engine owner, you should also be aware that Mack Trucks, Inc. may deny you warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
If you have any questions regarding your warranty rights and responsibilities, you should contact the Mack Trucks, Inc. Warranty Activities P.O.Box 26259, Greensboro, NC 27402, or the California Air Resources Board at 9480 Telstar Avenue, El Monte, California 91731.
(Applicable only to vehicles and/or engines certified for sale and registered
in the State of California) Mack Trucks, Inc. warrants the Emission Control Systems on each new MACK diesel engine in a new MACK truck to comply with all State of California emissions regulations applicable at the time of manufacture of the engine, and to be free from defects in material and workmanship under normal use and service up to
60 months, or 100,000 miles, or 3,000 engine operating hours, whichever occurs first, provided that all Mack Trucks, Inc. maintenance requirements are followed as described in this manual. All warranty periods are calculated from the date-in-service of the new vehicle. The repair or replacement of defective parts will be made without charge for the cost of parts and, if repairs are made at an authorized Mack Trucks, Inc. dealership, there will be no charge for labor.
Mack Trucks, Inc.’s obligation under this warranty is limited to the repair or replacement, at Mack Trucks, Inc.’s
option, of any part(s) of Emission Control Systems of such engine and/or vehicle foundtobedefectiveuponexaminationby Mack Trucks, Inc. and provided that such part(s) were returned to Mack Trucks, Inc. or its nearest authorized Dealer within a reasonable period of time.
Qualifications and Limitations:
Not covered by the Emissions Control Systems Warranty:
•Malfunctions caused by misuse, improper adjustments, modification, alteration, tampering, disconnection, improper or inadequate maintenance and use of improper diesel fuel or DEF.
•Damage resulting from accident, acts of nature or other events beyond the
•
•
Inconvenience, loss of use of the vehicle, commercial loss of any kind including, but not limited to, consequential or incidental damages.
Any vehicle in which the odometer has been altered or damaged so that mileage cannot be readily determined.
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18 INTRODUCTION
THISWARRANTYISEXPRESSLYINLIEUOFALLOTHERWARRANTIES AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Emissions Control System Warranty
The following engine components are covered by the supplemental emissions control system warranty policy as required by the California code of regulations.
1Turbocharger Assembly
•VGT Actuator
2Charge Air Cooler
•CAC Pipes (Air inlet to/from CAC)
•CAC Hoses
3Engine Control Module (ECM)
4Injectors
5Engine and Vehicle Wire harness ( repair to circuits related to Emissions Warrantable Components )
6Exhaust Gas Recirculation (EGR) Mixer
7EGR Cooler
8EGR Valve and EGR Valve Control
9EGR Pipes - Engine Exhaust Manifold to EGR Cooler
10EGR Pipes - EGR Cooler to Inlet Manifold
11Crankcase Breather
12Crankcase Separator
13Crankcase Tubing and Hoses before Separator
14Aftertreatment Wiring Harness
15AftertreatmentControlModule(ACM)
16Aftertreatment Diesel Particulate Filter (DPF) Assembly
A. Aftertreatment DPF Assembly with Aftertreatment Diesel Oxidation Catalyst (DOC)
•Aftertreatment Doser
•Diffuser Pipe (Aftertreatment Fuel Doser Mounting)
•Fuel lines to Aftertreatment Fuel Doser
•Aftertreatment Fuel Shutoff Valve
•Aftertreatment Fuel Pressure Sensor
•Engine Turbocharger Compressor Bypass Actuator (Heat Mode)
•Engine Turbocharger Compressor Bypass Actuator Solenoid
•Engine Exhaust Gas Temperature (EGT) Sensor
•Aftertreatment DPF Intake Temperature Sensor
•Aftertreatment DPF Outlet Temperature Sensor
•Aftertreatment DPF Differential Pressure Sensor
•Aftertreament Doser Air Supply Regulator (if applicable), Supply Lines, and Fittings
B. Thermal Regeneration Unit (TRU)
•Aftertreatment DPF Air Shutoff Valve
•Aftertreatment DPF Combustion Air Valve
•Aftertreatment DPF Atomization Module
INTRODUCTION 19
•Aftertreatment DPF Fuel Control Valve
•Aftertreatment DPF Ignition Electrode
•Nozzle
•Engine Exhaust Gas Temperature (EGT) Sensor
•Aftertreatment DPF Intake Temperature Sensor
•Aftertreatment DPF Outlet Temperature Sensor
•Aftertreatment DPF Spark Assist Flame Temperature Sensor
•Aftertreatment DPF Differential Pressure Sensor
17Sensors:
•Crankshaft Position (CKP)
•Camshaft Position (CMP)
•Engine Coolant Temperature (ECT)
•Intake Manifold Air Temperature
•Intake Manifold Pressure (IMP)
•EGR Temperature
•Aftertreatment Outlet NOx
•Aftertreatment Intake NOx
•EGR Differential Pressure
•Ambient Air Temperature (AAT)
18SCR
•Aftertreatment Selective Catalytic Reduction (SCR) Catalyst
•Aftertreatment Diesel Exhaust Fluid (DEF) Pump
•Aftertreatment DEF Dosing Absolute Pressure Sensor
•Aftertreatment DEF Return Valve
•Aftertreatment DEF Dosing Valve
•Aftertreatment DEF Tank
•Aftertreatment DEF Tank Heater/Sender
•Aftertreatment DEF Tank Heater
•Aftertreatment DEF Tank Heater Valve
•Aftertreatment DEF Tank Temperature Sensor
•Aftertreatment DEF Level Sensor
•Aftertreatment DEF Heated Lines
19.Instrument Cluster (Repair of microprocessor , OBD MIL, Real Time Clock, Aftertreatment DEF Tank Gauge and, Aftertreatment DEF Tank Low Level Indicator)
20.Exhaust Gas Piping (from Turbocharger to Aftertreatment System )
21.Data Link Connector (DLC)
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