Driver’s Handbook Mack EPA2010 Emissions Operator’s Manual

1 Driver s HandbookMack EPA2010 Emissions Operator s ManualForewordThis Manual contains information concerning the operation and functionof the mack Engines. Please keep this Manual in the vehicle at all :Illustrations in this Manual are used for reference only and maydiffer slightly from the actual vehicle. However, key componentsaddressed in this document are represented as accurately as National Highway Traffic Safety Administration (NHTSA) andMack Trucks, Inc. should be informed immediately if you believe thatthe vehicle has a defect that could cause a crash, injury or NHTSA by calling the Auto Safety Hotline at 1 (888) 327-4236,by writing to NHTSA, Department of Transportation, Washington,DC 20590, by TTY at 1 (800) 424-9153, or visit their website MackTrucks, , NC USAO rder number: PV776-21414253 2009 MackTrucks, Inc., Greensboro, NC USAA llrights 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, withoutthe prior written permission ofMack Trucks, of the mack 1 Introduction.

2 1 Fuel .. 2 Bio diesel .. 2 Engine Oil .. 2 Engine Operation .. 3 Engine Overview, MP7 and MP8 Left Side View .. 5 Engine Overview, MP7 and MP8 Right Side View .. 6 Engine Overview, MP10 Left Side View .. 7 Engine Overview,MP10 Right Side View .. 8 mack , EPA2010 Emissions 9 exhaust Aftertreatment System .. 9 Safety Information .. 11 exhaust Aftertreatment System Components and Operation .. 12 Selective Catalytic Reduction (SCR) .. 12 diesel exhaust Fluid (DEF) .. 14 Aftertreatment Control Module (ACM) .. 15 Aftertreatment diesel Particulate Filter (DPF) .. 16 exhaust Aftertreatment System Operation .. 17 Driver Warnings and On Board Diagnostics (OBD) .. 25On Board Diagnostics (OBD) .. 25 Instrument Cluster .. 25 Malfunction Indicator Lamp (MIL) .. 27 Aftertreatment DEF Tank Level - Driver Warning &Inducement .. 28 Aftertreatment DEF Quality - Driver Warning & Inducement .. 29 Misfilling diesel or Aftertreatment DEF Tanks.

3 30 SCR Tampering - Driver Warning & Inducement .. 31 Ambient Air Temperature (AAT) .. 32 Warranty and Maintenance .. 33 exhaust Aftertreatment System Maintenance .. 33 Emissions Maintenance .. 33 Engine Maintenance Intervals .. 33 Oil Change Intervals .. 35 Emissions Control System Warranty .. 36 Safety InformationIMPORTANT: Before driving this vehicle, be certain that you have read and that youfully understand each and every step of the driving and handling information in thismanual. Be certain that you fully understand and follow all safety IS IMPORTANT THAT THE FOLLOWING INFORMATION BE READ,UNDERSTOOD AND ALWAYS following types of advisories are used throughout this Manual :DANGERD anger indicates an unsafe practice that could result in serious personal injury or danger advisory banner is inwhitetype on ablackbackground with indicates an unsafe practice that could result in personal injury. A warningadvisory banner is inblacktype on agraybackground with indicates an unsafe practice that could result in damage to the product.

4 A cautionadvisory is inblacktype on awhitebackground with :Note indicates a procedure, practice, or condition that must be followed in order forthe vehicle or component to function in the manner PROPOSITION 65 WARNINGD iesel engine exhaust and some of its constituents are known to the State of California tocause cancer, birth defects and other reproductive PROPOSITION 65 WARNINGB attery posts, terminals and other related accessories contain lead and lead compounds,chemical known to the State of California to cause cancer and other reproductive also contain other chemicals known to the State of California to cause hands after new mack truck contains many new technological advancements that may require newservicing techniques and methods. An authorized mack truck dealer is in the best positionto provide technicians who have the necessary training, experience and tools to properlyservice your of the mack Engines1 IntroductionIn 2010, the mack engine family will consistof three engines: MP7, MP8 and mack engines meet the very stringentnew Emissions standards which apply toall heavy-duty diesel engines built afterJanuary 1, 2010 for on-highway trucks.

5 Thenew standards for EPA2010 requires 83%reduction in nitrogen oxide (NOx) and 0%reduction in Particles (Pt) relative to Features of the mack Engines: Improved Fuel Economy Extended Oil Drain Intervals Improved Cooling Capacity Low Maintenance CatalyzedAftertreatment diesel Particulate Filter(DPF) Enhanced Engine Brake Performance Selective Catalytic Reduction (SCR)2 Overview of the mack EnginesFuelCAUTIOND iesel engines for 2010 and later modelyear vehicles are designed to operate onlywith Ultra Low Sulfur diesel (ULSD)fuel. Use of fuel other than ULSD willreduce the efficiency and durability of theengine, permanently damage the advancedemission control systems, reduce fueleconomy and possibly prevent the enginefrom running at all. Manufacturer swarranties are likely to be rendered voidby usage of improper or incorrect fuel,and usage of fuels other than ULSD fuelin diesel -powered vehicles is illegal andpunishable with civil penalties. Use offuel additives to compensate for the lowersulfur content is NOT recommended byMack Trucks, sold for use in diesel -powered enginesfor 2010 and later model year vehicles mayonly contain a maximum sulfur content by weight.

6 This was done to reduceparticle Emissions in the DieselThe only BioDiesel Fuel approved by MackTrucks, Inc. for use in mack Engines is SoyMethyl Ester (SME or SOME) in blends upto B5 Concentration (5% blend).Note:Although higher concentrations areavailable, concentration up to B5 (maximum)are the only blends currently approved byMack Trucks, OilEO-O Premium Plus (or VDS-4) dieselengine oil is mandatory for use in all 2010emission compliant mack engines. Chassisequipped with a 2010 emission compliantengine, which can be identified by thepresence of an Aftertreatment SelectiveCatalytic Reduction (SCR) system, alsorequire the use of Ultra Low Sulfur diesel (ULSD) fuel. EO-O Premium Plus oilsexceed the new API service category of the mack Engines3 Engine OperationDANGERDo not use ether or other combustiblestarting aids in any mack of ether or similar startingaids could cause a fire or explosionresulting in severe property damage,serious personal injury or NOT crank the engine for more than30 seconds at a time; wait 15 minutesafter each try to allow the starter to to follow these instructions couldcause starter :Some starters are equipped withstarter protection.

7 If the engine is running,the starter temperature is too high, thetransmission is not in neutral or the clutchpedal is not depressed, starter engagementis the engine to slow down and idle for3 to 5 minutes before shutting it off. Thisallows the turbocharger to cool down and thecooling system to dissipate the engine the engine off by turning the ignitionkey to the OFF off an engine immediately afterhigh speed or full load operation candamage the turbocharger and cause heatstress in the engine. Always let the engineidle for 3 to 5 minutes before shutting Trucks, Inc. does not recommendthe use of winterfronts, shutters or anyother shield in front of the grille or radiatorpackage under normal s electronically controlled enginesare designed to operate in cold temperatureswithout a winterfront. These devices, ifnot used properly, can cause higher exhaustgas temperatures, power loss, excessive fanusage, failure of the charge-air-cooler anda reduction in fuel economy.

8 Winterfrontscan be used in the wintertime during verycold weather if used properly. In these cases,engine coolant and intake air temperaturesmust also be carefully monitored andcontrolled. Please see your authorizedMack Truck dealer for mack is now using the ambient airtemperature (AAT) sensor for OBDmonitoring. If a customer installs awinterfront or blocks the radiator openingand blocks airflow to the sensor, they willlikely set an OBD diagnostic trouble code(DTC) for inaccurate sensor data due torestricted airflow across the of the mack EnginesEngine Shutdown SystemDANGERF ailure to take the necessary precautionswhen the STOP telltale is on can result inautomatic engine shutdown and the loss ofpower steering. Vehicle crash can engine shutdown system willautomatically derate or stop the engine whenone or more of the conditions listed belowreaches a critical stage: High Engine Coolant Temperature(ECT) Low Engine Oil Pressure (EOP) Low Engine Coolant Level (ECL) High Crankcase Pressure (CCP)When the shutdown is activated, the telltalescome on along with display symbols and thebuzzer is also activated.

9 After a brief time,the engine shuts down. Find a safe place topull off the road as soon as the engine has been shut down bythe system, turn the ignition key to the offposition. If necessary, the engine can berestarted for a brief time so that the vehiclemay be pulled off the alarm will remain activated until repairshave been made to correct the problem thatcaused the restarting the engine oncethe shutdown system is active may resultin severe engine to the Driver Information Displaymanual for information about the of the mack Engines5 Engine Overview, MP7 and MP8 Left Side ViewW2006034MP8 Engine Shown, MP7 Engine Similar1. Breather Tube9. Fuel Filter2. Intake Manifold10. Hand-Priming Pump3. Air Compressor11. Crankcase Ventilator4. Power Steering Pump12. Alternator5. Fuel Pump13. AC Compressor6. Engine Control Module (ECM)14. Alternator/AC Compressor Belt7. Fuel Filter15. Fan/Coolant Pump Belt8. Fuel/Water Separator16. EGR Mixing Chamber6 Overview of the mack EnginesEngine Overview, MP7 and MP8 Right Side ViewW2006035MP8 Engine Shown, MP7 Engine Similar17.

10 exhaust Manifold24. Venturi Pipe18. Valve Cover25. Oil Filters19. Intake Air Heater (IAH) optional26. Oil Pan20. Thermostat27. EGR Cooler21. Belt Tensioner28. Turbocharger22. Coolant Pump29. Starter Motor23. Coolant Filter30. EGR ValveOverview of the mack Engines7 Engine Overview, MP10 Left Side ViewW20060371. Breather Tube9. Fuel/Water Separator2. Intake Manifold10. Fuel Filter3. Air Compressor11. Hand-Priming Pump4. Power Steering Pump12. Alternator5. Fuel Pump13. AC Compressor6. Crankcase Ventilator14. Alternator/AC Compressor Belt7. Engine Control Module (ECM)15. Fan/Coolant Pump Belt8. Fuel Filter16. Venturi Pipe17. EGR Mixing Chamber8 Overview of the mack EnginesEngine Overview,MP10 Right Side ViewW200603618. exhaust Manifold24. Coolant Filter19. Valve Cover25. Oil Filters20. Intake Air Heater (IAH)26. EGR Cooler21. Thermostat27. Oil Pan22. Belt Tensioner28. Starter Motor23. Coolant Pump29. Turbocharger30.