Mack TD700 Series Operator Manual

TITAN by MACK (TD700 Series)

April 2010

Foreword

Thismanualcontainsinformationconcerningtheoperationand functionofthe MackLinkSystem.Theinformationinthismanual appliestovehiclesbuilt April2010andlater.Pleasekeepthismanual inthevehicleatalltimes.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay differslightlyfromtheactualvehicle.However,keycomponents addressedinthisdocumentarerepresentedasaccuratelyaspossible.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)and V olvoTrucksNorthAmericashouldbeinformedimmediatelyifyou believethatthevehiclehasadefectthatcouldcauseacrash,injury ordeath.

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

Mack Trucks Inc.

Greensboro,NCUSA

Ordernumber:PV776-21394652

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

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

WARRANTYINFORMATION..................................................................................11

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

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................11

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

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

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

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

EmissionsControlSystemWarranty.......................................................................18

SERVICELITERATURE............................................................................................22

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

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

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

Call1-800-866-1177forMACKOneCall™...........................................................23

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

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

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

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

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

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

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

EVENTDAT ARECORDINGDEVICES...................................................................27

.................................................................................................................................27

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

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

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

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

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

AdvisoryLabelLocations(OnVehicle)..................................................................33

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

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

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

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

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

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

SAFETYTIPSFORCOLDWEATHEROPERATION.............................................52

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

CabDoorSealsandKeyLocks...............................................................................53

OutsideMirrorHeater..............................................................................................53

AirHornSnowShield..............................................................................................54

EmergencyReectorKit..........................................................................................54

FireExtinguisher(Optional)....................................................................................54

INSTRUMENTSANDCONTROLS...........................................................................55

CABINTERIOR..........................................................................................................55

INSTRUMENTPANEL..............................................................................................56

Tell-T ales..................................................................................................................56

PanelArrangement...................................................................................................57

INSTRUMENTPANELGAUGELAYOUT..............................................................58

PanelA.....................................................................................................................60

PanelB.....................................................................................................................61

PanelC.....................................................................................................................63

PanelD.....................................................................................................................64

FunctionofOptionalSwitches.................................................................................77

CABCLIMATECONTROL.......................................................................................84

LIGHTCONTROLP ANEL........................................................................................86

LOWERCONSOLEP ANEL......................................................................................87

STEERINGCOLUMN................................................................................................88

CombinationStarterandElectricalSwitch..............................................................88

SteeringWheelAdjustment.....................................................................................88

TurnSignalLever....................................................................................................89

StalkSwitch(IfEquipped,Co-Pilot®Only)...........................................................90

FLOORPEDALS........................................................................................................92

MISCELLANEOUSCONTROLS..............................................................................93

DomeLight..............................................................................................................93

AirHorn...................................................................................................................94

FreshAirV ent..........................................................................................................94

CabAirFilter...........................................................................................................95

Microphone..............................................................................................................95

AccessoryPowerOutlets.........................................................................................96

OPERATION..................................................................................................................98

PRE-TRIPINSPECTIONANDDAILYMAINTENANCE.......................................98

Pre-TripInspectionQuickList................................................................................99

NewVehicleBreak-In............................................................................................110

WINDSHIELDWASHERRESERVOIR..................................................................112

HOODOPERATION.................................................................................................113

OpeningtheHood..................................................................................................113

ClosingtheHood...................................................................................................114

LockingtheHood..................................................................................................115

HOSETENDERS......................................................................................................117

DOORS......................................................................................................................118

PowerDoorPanel(Optional).................................................................................118

OpeningtheCabDoor...........................................................................................119

LockingtheCabDoor............................................................................................120

PowerWindowRegulators....................................................................................120

REMOTEKEYLESSENTRY—(OPTIONAL)......................................................121

TransmitterOperations..........................................................................................122

BatteryReplacement..............................................................................................123

SEATBELTS.............................................................................................................126

SeatBeltOperation................................................................................................126

FasteningSeatBelt................................................................................................126

AdjustableD-RingShoulderBelts(ifequipped)...................................................128

Komfort®LatchSystem........................................................................................129

SEATADJUSTMENTANDRECLINE(IFEQUIPPED)........................................131

MIRRORBREAKAW A YSTRUT............................................................................132

MACKENGINEINFORMA TION...........................................................................133

PrecautionsandW arnings......................................................................................133

EngineModelDesignations...................................................................................135

TIREPRESSURECONTROLSYSTEM(IFEQUIPPED)......................................136

OperatingtheDanaTirePressureControlSystem................................................137

TireChangingProcedure.......................................................................................142

CRUISECONTROLOPERA TION..........................................................................144

SpeedControlSwitches.........................................................................................144

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

DisengagingCruiseControl...................................................................................145

MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................146

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

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

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

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

OverFlatT errain....................................................................................................150

DescendingaGrade...............................................................................................151

OnSlipperyRoadSurfaces....................................................................................153

BRAKEOPERATION...............................................................................................155

AirBrakeSystem...................................................................................................155

AutomaticSlackAdjusters....................................................................................156

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

ParkingBrakeOperation........................................................................................157

Parking...................................................................................................................157

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

AutomaticTractionControl(A TC)(IfEquipped).................................................161

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

COLDWEATHEROPERA TION.............................................................................171

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

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

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

COUPLINGATRAILER..........................................................................................175

UNCOUPLINGATRAILER....................................................................................177

MOVINGTHEVEHICLE—GENERALINFORMA TION...................................179

Braking...................................................................................................................179

Shifting...................................................................................................................179

EngineTemperature...............................................................................................180

Clutch(IfEquipped)..............................................................................................180

POWERTAKE-OFF(PTO)OPERATION...............................................................185

PTOPrecautions....................................................................................................185

PTOClassication.................................................................................................186

Side-MountedPTOLocations...............................................................................186

PTOOperatingProcedures....................................................................................186

TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................187

MACKT310ShiftingInstructions........................................................................188

MACKT310ME21ShiftingInstructions..............................................................191

MACKT31321andT313LR21ShiftingInstructions...........................................194

MACKT31821andT318LR21ShiftingInstructions...........................................198

AXLES.......................................................................................................................204

RearAxlesOtherThanMACK.............................................................................204

MACKRearAxles.................................................................................................204

EngagingthePowerDividerLockout....................................................................205

ExtendedIdlingandAftertreatmentSystemConditioning.......................................207

Mack,EPA2010EmissionsSolution...........................................................................208

DIESELPARTICULA TEFILTERS(IFEQUIPPED)..............................................208

ExtendedIdlingandAftertreatmentSystemConditioning...................................211

ExhaustAftertreatmentSystem.................................................................................212

SafetyInformation.................................................................................................213

ExhaustAftertreatmentSystemComponentsand................................................214

SelectiveCatalyticReduction(SCR)....................................................................214

DieselExhaustFluid(DEF)...................................................................................217

AftertreatmentDieselParticulateFilter(DPF)......................................................220

AftertreatmentControlModule(ACM).................................................................221

ExhaustAftertreatmentSystem............................................................................222

DriverWarningsandOnBoardDiagnostics(OBD).............................................227

OnBoardDiagnostics(OBD)................................................................................227

InstrumentCluster..................................................................................................228

MalfunctionIndicatorLamp(MIL).......................................................................229

AftertreatmentDEFT ankLevel-DriverWarning&Inducement........................230

AftertreatmentDEFQuality-DriverW arning&Inducement..............................231

MisllingDieselorAftertreatmentDEFT anks.....................................................232

SCRTampering-DriverW arning&Inducement.................................................233

WarrantyandMaintenance....................................................................................234

ExhaustAftertreatmentSystemMaintenance........................................................234

EngineMaintenanceIntervals................................................................................234

MAINTENANCEANDLUBRICA TION..................................................................235

MAINTENANCEINTRODUCTION.......................................................................235

TURBOCHARGER...................................................................................................236

CLEANINGYOURVEHICLE.................................................................................237

ExteriorWashing...................................................................................................237

CabandHood........................................................................................................239

Chassis...................................................................................................................239

CabInterior............................................................................................................240

Waxing...................................................................................................................240

Polishing................................................................................................................240

WinterWarnings....................................................................................................240

TOWING...................................................................................................................241

AIRCLEANER.....................................................................................................242

ENGINEOILLEVELCHECK.................................................................................243

PowerSteeringReservoir......................................................................................244

FUELTANK..............................................................................................................246

FuelTankCap........................................................................................................246

FUELING..................................................................................................................247

BioDiesel................................................................................................................248

B20ApprovalForMackEPA07CertiedProducts.............................................248

COOLINGSYSTEM.................................................................................................249

CoolantLevelCheck..............................................................................................249

DrainingtheCoolingSystem.................................................................................250

RellingtheCoolingSystem.................................................................................251

ProtectingtheCoolingSystem..............................................................................251

CoolingSystemMaintenance................................................................................252

AccessoryDriveBeltRouting...............................................................................253

HEADLIGHTS..........................................................................................................254

BulbReplacement..................................................................................................254

LICENSEPLATEMOUNTING...............................................................................254

WHEELS...................................................................................................................255

WheelInspection...................................................................................................255

Tires.......................................................................................................................256

BATTERY..................................................................................................................259

Jump-StartingEngine.............................................................................................259

ELECTRICAL...........................................................................................................261

CircuitBreakerandRelayPanels..........................................................................261

ElectricalGrease....................................................................................................263

ElectricalAccessoryConnectionPoints................................................................267

METRICCONVERSIONS.........................................................................................275

METRICCONVERSIONS.......................................................................................275

SafetyInformation

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

ITISIMPORTANTTHA TTHE FOLLOWINGINFORMA TIONBE READ,UNDERSTOODANDALW AYS FOLLOWED.

Thefollowingtypesofadvisoriesareused throughoutthismanual:

DANGER

Dangerindicatesanunsafepracticethat couldresultinseriouspersonalinjury ordeath.Adangeradvisorybanneris inwhitetypeonablackbackground withablackborder .

WARNING

Warningindicatesanunsafepractice thatcouldresultinpersonalinjury.A warningadvisorybannerisinblack typeonagraybackgroundwithablack border.

CAUTION

Cautionindicatesanunsafepracticethat couldresultindamagetotheproduct. Acautionadvisoryisinblacktypeona

whitebackgroundwithablackborder.

Note:Noteindicatesaprocedure,practice,

orconditionthatmustbefollowedinorder forthevehicleorcomponenttofunction inthemannerintended.

INTRODUCTION1

TOTHEOWNER

InAppreciation

ThankyouforbuyingaMACK®vehicle.Withpropercareandmaintenance,your newMack®TD700modelwillhelpyougainacompetitiveedgewithitsfuel-efcient drivetraincombinations,lowmaintenance,extendedserviceintervalsand,eventually, goodresalevalue.

TheMack®TD700modelisavailableforawiderangeofapplications. Becauseofthisversatility ,drivetrainsandcomponentsvaryandoperating instructionsmaydifferfromonemodeltoanother.Whileeveryefforthas beenmadetocoverallcurrentarrangements,donothesitatetoconsultyour MACKdistributorifaquestionarises.Honest,personalserviceisstandard witheveryMACKsale.

CAUTION

MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.

We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack® TD700model,andthatyouseemanyyearsoftrouble-freedriving.

Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations applicableatthetimeofmanufacture.

2INTRODUCTION

AboutThisHandbook

ThishandbookisreferredtoastheMack®TD700SeriesOperator’s Handbook.ItcoversallMack®TD700models.Itsidenticationnumberis

213946521.Keepthishandbookwiththevehicleatalltimestoensurethat eachownerand/oroperatorwillhaveaccesstoallpertinentinformation relatingtotheoperationandhandlingofthisvehicle.

Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation concerningthedailyoperationofthisvehicle.Pleasereaditthoroughly; payparticularattentiontoadvisorylabelsthathavebeenincludedtodraw attentiontoimportantissuesofoperatorsafetyandoverallperformance.

Informationandillustrationsinthishandbookarebasedonthelatest productionusageatthetimeofprintingandaresubjecttochangewithout priornotice.

Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual beginningwith“MAINTENANCEINTRODUCTION”,page235.Forfurther information,refertotheMaintenanceandLubricationManual(21394653).Other importantinformationcanbefoundintheEmissionControlSystemsforMACK DieselEngineManual.

INTRODUCTION3

THEVEHICLE

BasicConguration

TheMack®TD700modelfeaturesaconventionallystyled,aerodynamiccab.

VehicleManagementandControlSystem (V-MAC®)

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

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

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

WARNING

NevercutintotheV-MACsystemwireharnesstopoweradditionalequipment.If suchequipmentistobeinstalled,contactyourMACKdealerforassistance.

4INTRODUCTION

COMPONENTIDENTIFICATION

Locatethefollowingserialnumbersandwritethemintheboxesprovided nexttoeachillustration.

VINLocations

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

TheVINframestampingislocatedontherightoutsideframerailandthe leftinsideframerail.

TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.

C0029937

C0028941

INTRODUCTION5

EngineIdentication

OntheMACKMPengines,theengineserialnumberisstampedontheleft sideoftheengineblock,belowtheinletmanifold.

C0028943

6INTRODUCTION

EngineInformationPlate

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

W2040455

EngineIdenticationLabel-49StateEP AApprovedEngine

withoutCalifornia"CleanIdle"

EngineIdenticationLabel-50StateEP AApprovedEngine

withCalifornia"CleanIdle"

W2040456

INTRODUCTION7

CleanIdleEngines

TheCaliforniaAirResourcesBoard(ARB)requiresthat2008modelyear vehiclesbeequippedwithengineshavingtamper-resistantsoftwarewhich limitsthetimeatwhichtheenginecanidleatspeedsabovelowidle(550–700 rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idletimewill belimitedtoveminutes,afterwhichtheenginewillrevertbacktolowidle. VehiclesequippedwithaCleanIdleengineareidentiedbyalabelwhichis afxedtotheleftfrontcornerofthehoodonconventionalmodels(TD700).

CleanIdleEngineLabel

W2056289

8INTRODUCTION

TransmissionIdentication

TheMACKT300Seriestransmissionserialnumberislocatedontherear leftsideofthemaincase.

C0028947

AllEaton®Fuller®transmissionidenticationplatesarelocatedonthe frontleftsideofthemaincase.

C0028949

TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside ofthehousing.

C0028950

TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe axlehousingtowardthecarrier.

INTRODUCTION9

C0028951

TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft sideoftheforwardcarrier,andthetopoftherearcarrier.

C0028952

TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof therearaxlehousing,nexttothecarrier.

C0028953

10INTRODUCTION

TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof theforwardcarrier,andthetopoftherearcarrier.

C0028954

INTRODUCTION11

WARRANTYINFORMATION

ThischassisisequippedwithaUS10emissioncompliantengineandan exhaustaftertreatmentsystem(DieselParticulateFilter).UseofUltraLow SulfurDiesel(ULSD)fuelandEO-OPremiumPlus(orVDS-4)specication highperformancedieselengineoilisrequiredinthisvehicle.

Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand aftertreatmentsystem(DieselParticulateFilter)warranty .2007emissionengines R

E Q U I R E theuseofEO-OPremiumPlus(orVDS-4)specicationhighperformance

dieselengineoilandUltraLowSulfurDiesel(ULSD)fuel.

AirBrakeSystem

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

Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.

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

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

Forcompletewarrantyinformation,refertothePedigreedProtectionPlan providedwitheachvehicle.

ENGINEGASEOUSEMISSIONCONTROL SYSTEMS

WARRANTYMAINTENANCE

Note:Foremissioncontrolsystems informationonenginesotherthanMACK, refertotheenginevendor’spublication

12INTRODUCTION

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY

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

QualicationsandLimitations:

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.

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.

THISWARRANTYISEXPRESSLYINLIEUOFALLOTHERW ARRANTIES ANDREPRESENTATIONSORCONDITIONS,ST ATUTORYOR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA PARTICULARPURPOSE.

INTRODUCTION13

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandVehicleWireharness(

repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRValveandEGRV alveControl

9EGRPipes-EngineExhaustManifold

toEGRCooler

10EGRPipes-EGRCoolertoInlet

Manifold

11CrankcaseBreather

12CrankcaseSeparator

13CrankcaseTubingandHosesbefore

Separator

14AftertreatmentWiringHarness

15AftertreatmentControlModule(ACM)

16AftertreatmentDieselParticulateFilter

(DPF)Assembly

A.AftertreatmentDPFAssembly withAftertreatmentDieselOxidation Catalyst(DOC)

•AftertreatmentDoser

•DiffuserPipe(AftertreatmentFuel

DoserMounting)

•FuellinestoAftertreatmentFuel

Doser

•AftertreatmentFuelShutoffV alve

•AftertreatmentFuelPressureSensor

•DischargeRecirculationV alve

(DRV)(HeatMode)

•DischargeRecirculationV alve

(DRV)Solenoid

•EngineTurbochargerCompressor

BypassActuator(HeatMode)

•EngineTurbochargerCompressor

BypassActuatorSolenoid

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFCombustion

AirControlValve

•AftertreatmentDPFCombustion

AirV alve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

14INTRODUCTION

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantT emperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRT emperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AAT)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingValve

•AftertreatmentDEFTank

•AftertreatmentDEFT ank

Heater/Sender

•AftertreatmentDEFTankHeater

Valve

•AftertreatmentDEFT ank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

19.InstrumentCluster(Repairof microprocessor,OBDMIL,RealTime Clock,AftertreatmentDEFT ankGauge 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’SW ARRANTY 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 SystemsW arranty:

•Malfunctionscausedbymisuse,

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

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe

controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

18INTRODUCTION

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheCaliforniacodeofregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandVehicleWireharness(

repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRValveandEGRV alveControl

9EGRPipes-EngineExhaustManifold

toEGRCooler

10EGRPipes-EGRCoolertoInlet

Manifold

11CrankcaseBreather

12CrankcaseSeparator

13CrankcaseTubingandHosesbefore

Separator

14AftertreatmentWiringHarness

15AftertreatmentControlModule(ACM)

16AftertreatmentDieselParticulateFilter

(DPF)Assembly

A.AftertreatmentDPFAssembly withAftertreatmentDieselOxidation Catalyst(DOC)

•AftertreatmentDoser

•DiffuserPipe(AftertreatmentFuel

DoserMounting)

•FuellinestoAftertreatmentFuel

Doser

•AftertreatmentFuelShutoffV alve

•AftertreatmentFuelPressureSensor

•EngineTurbochargerCompressor

BypassActuator(HeatMode)

•EngineTurbochargerCompressor

BypassActuatorSolenoid

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFAirShutoff

Valve

•AftertreatmentDPFCombustion

AirV alve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

INTRODUCTION19

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantT emperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRT emperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AAT)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingValve

•AftertreatmentDEFTank

•AftertreatmentDEFT ank

Heater/Sender

•AftertreatmentDEFTankHeater

Valve

•AftertreatmentDEFT ank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

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

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

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