TECHNICAL SUPPORT TIPS

New Item Customer Interviews Description Follow Basic Data Gathering Bulletin Reference SB 030-01 (Mack) SB 030-57 (Volvo) Comment / Symptom / Repair For most repairs, especially inducement faults and faults w/ no DTCs (symptoms only reported)

SPN 5394 / FMI 17 SPN 4094 / FMI 18

US10 Catalyzed SCR System Performance

Mack and Volvo

US10 11L, 13L, 16L, SNM 13-022 and SNV 13-021 (TDP/service/news & info) Follow Revised Inducement Exit Strategy 4094J (jobcard of sensor values) prior to submitting eSvc case. Attach jobcard of sensor values in .html format when opening eService and list all results of performing 4094J. (TDP/service/tech support/FG2)

SPN 4094 / FMI 1, 18 SPN 5246 / FMI 0, 15, 16

US10 Non-Catalyzed SCR Performance

Mack only (MRU/LEU)

SPN 100 / FMI 1 and P052400 Low Oil Pressure

11L EPA2010, OBD2013 engines

Mack and Volvo

Code logs during long hard pull conditions, with or without an engine shutdown lamp; refer to FSB 221-010, revised 9.2013

SPN 4811 / FMI 1 & 2

13L EPA2010 Piston Cooling Oil Pressure

Mack and Volvo

See FSB 284-039 dated 12.2012

Updated Injector Sleeve Tools

88800387, 88800457, 88800460

Mack and Volvo

See SNM 13-036; SNV 13-035 dated 9/11/13 (both documents in TDP/service/news and info) For details and training video.

US10 11L Injector Enhancements

Misfire under Load US10 only

Mack and Volvo

See SNM 13-026 (Mack); SNV 13-025 (Volvo), both dated 6/14/2013. (both documents in TDP/service/news and info)

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New Item US10 and US13 13L Injector Enhancements US10 16L Injector Enhancements Description Misfire under Load US10 and US13 Misfire under Load US10 only Reference Mack and Volvo Comment / Symptom / Repair See SNM 13-021 (Mack) ; SNV 13-020 (Volvo), both dated 5/31/13. (both documents in TDP/service/news and info) See SNM 13-024 (Mack); SNV 13-023 (Volvo), both dated 6/14/2013. (both documents in TDP/service/news and info) Vehicles build date prior to 5/5/13 (Mack, eng clean point 1027921) and 5/4/13 (Volvo, engine clean point 1027785), see FSB 237-018 (dated 5.2013) relative to replacement of injector kit, programming the ECM w/ new injector trim codes, and installation of fuel tank filter vent kits. See SNM 13-40 and SNV 13-39, dated 11/5/13 (TDP/Service/News & Info) SB 237-60, Release 2 Engine Injector and Sleeve, Replacement (Conical) Describes important tools and procedure; replaces all existing tools and procedures for conical sleeve replacement. SB 237-61 Engine Injector and Sleeve, Replacement (Conical) Checklist Can be used to remove both copper and conical sleeves. (both documents in TDP/service/tech support/FG2) SB 237-60 Conical Unit Injector and Sleeve (both documents in TDP/service/tech support/FG2) Issue is being closely evaluated by engineering and a production and aftermarket solution is under development. This is not considered safety related and is primarily due to the shoes made of a more aggressive material and the time required for a full burnishing has increased.

Mack and Volvo

US13 (OBD2013) Conical Injector Kits

13L CHU, CXU, GU VAH, VHD, VN

Mack and Volvo

SPN 641 / FMI 7

11L / 13L

Mack and Volvo

SB 237-60, Release 2 SB 237-61

New Removal Tools

Mack and Volvo

Unit Injector and Sleeve, Replacment (Conical) 11L, 13L, 16L

11L, 13L, 16L

Mack and Volvo

Brake Noise

Scuffing of drums, shoes, and end play checks are not warrantable

Mack and Volvo

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New Item SPN 3675 / FMI 7 Description Follow PTT/GD Following install, prior to programming, if fault codes 5-8, 5-9, 6-7 are active at key on Reference Mack and Volvo Comment / Symptom / Repair If NFF, engine off, key on, check boost psi in VCADS; if reading boost (ex: 6 psi), most likely a boost sensor failure. Do not diagnose the active fault codes, order a new EECU, same part number. Module with Date Code of 130225 or greater is a good module see TDP/service/tech support/VMAC I, II, III for location of date code. Norcold contact info: http://norcold.com and phone 1-800543-1219 and 1-734-769-6000 http://www.bendixvrc.com/itemDisplay.asp?documentID=6030 (document also in TDP/service/tech support/FG5). (TDP/service/tech support/US 2010) Effective immediately, for HP Conversion requests, submit an eService to Parts Specifications.

VMAC III EECU part number 12MS534M new controller

Mack only

Norcold Refrigerator

Mack and Volvo

Bendix Disc Thermal Overload MRU / LEU DEF Heating Line HP Conversions Routing Parts Bulletins being revised. Noticeable changes; 1. diagnostic connector, 2. Fault codes begin with Pxxxx (or Uxxxx), for SA-0 (formerly MID 128), MID 233, MID 130.

Mack and Volvo Mack MRU / LEU Mack and Volvo

US13 OBD

Mack and Volvo

Diagnostic Connector change from 9-Pin to 16-pin rectangular connector SAE J1962. Contact Tech Support via eService for fault codes that begin with Pxxxx (Uxxxx for communication link) (formerly SPN codes for US10).

DEF Pump Replacment

Pump replacement caused by contamination

Mack and Volvo 3

DEF Circuit (tank, level sensor, DEF lines) must be properly cleaned. Use clean water only (DO NOT USE DETERGENT). See procedure for Cleaning the DEF Circuit after a Pump Failure (TDP/service/tech support/FG2)

January 15, 2014

TECHNICAL SUPPORT TIPS

New Item Description Engine Coolant Thermostat Software Update Reference Mack (CHU, CXU, GU, TD, MP7, MP10) Volvo (VN, VHD, VAH, D11H, D16H) Comment / Symptom / Repair During severe weather conditions, fault may display during engine warm-up and indicate an issue even when the cooling system is performing normally. DTC can be removed from the diagnostics by updating MID 128 (SA-0) Software See FSB 284-038 (Same FSB # for both brands)

SPN 1659 / FMI 12

DEF (Diesel Exhaust Fluid) lines

At top of DEF tank, lines may break in extreme cold temperatures Located in IMPACT US 2013 US 2013

Mack and Volvo

When trucks are not run on a daily basis, in temperatures below -11 C (-12 F), DEF tank levels should be no higher than 1/2 a tank, to allow for expansion as DEF freezes. Failure to do so may lead to damage to DEF lines or connections. Also in TDP/service/tech support/US 2013 - OBD PTT 2.01 OBD 2013 Training CD sent with DVD release of TT2 (also in LMS) 1065-EN: Volvo Tech Tool 2.0 e-learning (in LMS) At each use, check for Client Updates Update Client Updates, then Update Product information also, then reboot of laptop is required. Recommend use of landline if any issues during update using wireless. See TT2-Client Update and Update Product Information in TDP/service/tech support/US 2013OBD Related to USER ID issue; please contact VOLVO IT at 1-877978-6586 If you get a pop up about inconsistent parameters and cannot change them, to ignore the pop up as it will not affect truck operation. P1AFT with a value of 254 is one of them commonly seen.

OBD 2013 Monitors /DTCs Tech Tool 2 (TT2) training Tech Tool 2 (TT2) training

Mack and Volvo Mack and Volvo Mack and Volvo

TT2 Updates

US 2013

Mack and Volvo

TT2 programming

Error Code 4007

Mack and Volvo

TT2 parameter programming

PF1AFT

Mack and Volvo

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New Item Wiring Schematics Description Legacy, US04, US07, US10 US07, US10 Clearance between cab body/engine User Guide Reference Mack and Volvo Comment / Symptom / Repair TDP/service/tech support/wiring schematics Complete Failed Regen Sensor Values in TDP/service/tech support/FG2 Ref: FSB 811-007, Body Panel, Installation (Cab to Engine Clearance) TDP/service/tech support/US 2013 OBD All 3 modules will be allowed for use on warranty repairs: 1. Complete unit should still be used if cost of repairs is 75% of reman 2. Basic unit (less shift housing & TECU) will be best option for tow damage 3. Short unit (less shift housing, TECU, & auxiliary range section) will be best option for bearing failure or main shaft synchronizer issues. I-Shift / M-Drive Repairs Mack and Volvo Parts will be available for dealers to repair auxiliary range section in addition to a complete unit. Dealer is responsible to assess unit and select best repair option. Technicians must attend on-line training before using modules for repairs. Dealer assumes all risk of assembly workmanship. Ref: SB 431-12 (short) and SB 431-13 (basic), PSM-13-V-NA-10 and V42-1 for Volvo p/n and PSM13-NA-13 and M42-1 for Mack p/n. In VCADS the svc regen function 254508-03-03, System State field populated with Error (No DTC)

Regen Issues MRU w/Cummins Natural Gas Engine Premium Tech Tool 2

Mack and Volvo

Mack only Mack and Volvo

US10, MP7, MRU/LEU unable to perform Service Regenerations

Mack

Reference SNM 13-009 for temporary diagnostic procedure until new software is developed. (TDP/Service/News & Info)

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New Item VCADS OP 1700-08-03-06 Sensor Values and Monitoring Description Exporting values to Microsoft Excel Reference Mack and Volvo Comment / Symptom / Repair Reference .ppt document in TDP/Service/tech support/FG2 To install a stanchion mounted fuel tank vent kit on trucks with cab mounted exhaust, identify a suitable fixed mounting point preferably near the back of the cab at a point above the fuel tanks; high enough to allow for the vent line to be routed on an upward slope. If a body is being mounted to the truck a fixed point on the body near the back of the cab and above the tanks can be used as well. Route the vent lines in an upward sloping direction away from the tank so fuel can drain back to the tank from fuel tank slosh. Do not leave any droops or low points in the hose routing that would allow fuel to sit or collect in the vent line.

Fuel Tank Ventilation Filter Kit mounting with cab-mounted exhaust

FSB 234-014 installing a stanchion mounted fuel tank vent kit for trucks with cab-mounted exhausts

Mack and Volvo

SPN 84 / FMI 19

VSS sensor fault

Mack (M-Drive) and Volvo (-Shift)

As a short term solution do the following: Install a 2mm gasket, p/n 977935, between a known good AMT Vehicle Speed Sensor and the Automated Maunaul Transmission. For parts marked 21643804 up to date code 49 12 (w1249), replace with p/n 21643804 date code 50 12 (w1250) or greater and add gasket p/n 977935. For parts marked 21643804 date code 50 12 (w1250) or greater, remove sensor add gasket p/n 977935 and re-install. Sensor torque is 25 +/- 5 Nm Release the truck to the field. A long term solution is being developed and further service documentation will follow once completed.

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New Item eService tip Description Reference Mack and Volvo Comment / Symptom / Repair Please do not reply to an eService activity with Thank you, or Will let you know as this changes the position of the case from your database to ours. Furnish only requested information. Thank you.

US10 11L

EGR Differential Pressure Sensor Tuble Clearance Checks

Mack and Volvo

See SNM 13-027 (Mack) ; SNV 13-026 (Volvo), both dated 6/19/13. (both documents in TDP/service/news and info)

US10 13L

Low Power and Incomplete Regens

Mack and Volvo

Check turbo mtg gasket; have found US07 turbo mtg gskt (21137579) w/ restrictor hole installed in the field erroneously, instead of a US10 mtg gskt (20781146) w/ open hole. Make a quick check; the incorrect US07 gskt has tabs at the end. Reference .ppt document in TDP/Service/tech support/FG2

eService tip

I-Shift / M-Drive Replacement

Mack and Volvo

Remember to provide both the New and Old transmission model and serial numbers. For SPN 412 FMI 0 fault code continue diagnostic procedure as normal (if SPN 412 FMI 5/15 codes are not present), issue could be EGR cooler related. SPN 412 FMI 15 If above 15 counts, replace sensor (no diagnostics needed fault code printout must be attached to the claim as proof the codes are there). SPN 412 FMI 5 If above 15 counts, replace sensor (no diagnostics neededfault code printout must be attached to the claim as proof the codes are there). FMI 5/15 trumps the FMI 0, if combination of these FMIs.

SPN 412 / FMI 0, 5, 15

EGR Temp Sensor

Mack and Volvo

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New Item TT2 Group View of TEA2+ parameters (now called DOIDs) Description Reference Mack and Volvo Comment / Symptom / Repair Cross Reference List of DOIDs vs parameters from pre US 2013 OBD, with descriptions (will be a SB in the future) TDP/Service/tech support/US 2013 OBD Do not spend any time on this issue right now - goes away when the engine reaches operating temperature. Do not replace injectors, VCB valves or major engine components as the issue is software. A fix will be incorporated in an upcoming software campaign. The chassis can be released for now till the campaign is released. This creates no engine damage. Most customers will not even notice the issue because it does not happen under load. TDP/Service/tech support/US 2013 OBD Engine ECU MSW is: 22208328P01 22208329P01 22208345P01 22208346P01 Occurs when engine coolant is cold (<80c, 176F) and engine did not go past 1200 rpm. Temp solution run until coolant up to operating temp (80 deg C, 176 deg F). Use pedal to raise eng speed to 1200 RPM momentarily, the allow truck to return to idle, start either regen or sublimation tests within 2 minutes of truck coming back to idle. Permanent solution Engine ECU s/w update tentative w1338 or later.

OBD2013 HDE 11 Engine stumble under low load condition

engines built with software later than W1307, if a stumble issue at 1200-1600 when cold and under light load

Mack and Volvo

OBD2013 Electrical System Version 3 parameters

SB 000-03

Mack and Volvo

OBD2013 Parked Regeneration Failure (Code 43)

While performing 2545-08-03-03 (regen) or 2585-1103-03 (SCR sublimation)

Mack and Volvo

Agility Fuel Systems (Natural Gas fuel systems)

CNG/LNG

Mack and Volvo 8

Technical Support Line 949-267-7745 e-mail: support@agilityfs.com www.agilityfuelsystems.com Service/Warranty, Technical Support, Training, Aftmkt Parts

January 15, 2014

TECHNICAL SUPPORT TIPS

New Item OBD2013 ECM ACM TCM Description Diagnostic Trouble Codes (DTCs) Reference Mack and Volvo Comment / Symptom / Repair TDP/Service/tech support/US 2013 OBD Float Level Sending Unit resistance test Specifications, Design and Function, and Troubleshooting (Group 38 document in TDP/service/tech support/FG3) Technical Assistance, contact Dometic @ 1-800-234-8778 or 1804-746-1313. When programming a Cummins ECM via INSITE software, perform ECM Image, to capture the programmed customer parameters in the Cummins ECM. If done at a Cummins distributor, request a printout of the expanded parameter list. Click on Help in upper rt corner of TDP for software downloads & links, including PTT & VCADS downloads. This fault code does not mean the system has issues, it simply means that the truck is not signed up to an active account in Volvo Link. Until the truck is signed up and activated, TGW will not communicate. Wrong flywheel housing may have been installed. The AMT flywheel hst is not the same depth as the non-AMT housing. This causes a large change in the X2 value (30.6 mm) that is higher than the saved X1 value (26.0 mm). Check VCADS clutch wear check, test. Verify flywheel hsg PN prior to installation of new hsg or repl engine.

Fuel Level Sending Unit

VN, VHD, VT, VAH

Volvo

Dometic HVAC

Tech Support

Volvo

Cummins ECM Programming

To save factory settings for Multiplexing codes Formerly Software / PC

Mack and Volvo

Software Downloads (location)

Mack and Volvo

Volvo Link / TGW

MID 142, PSID 1, FMI 12, 13

Mack and Volvo

AMT operational issues or clutch calibration issues after engine or flywheel hsg replacement

Vehicle will not move and engine RPM will not increase when shifter put in gear, or AMT will not calibrate if TECU reprogrammed

Mack and Volvo

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New Item CAC Flux Contamination, may result in engine surge, especially at low idle or low RPM. Contamination of mixer flow ports with a gray/white crusty substance. Description Reference Comment Recommendation is to send the CAC to a radiator shop to be cleaned locally, do not replace the CAC. Claims will be accepted for cleaning or replacement of the affected Cummins parts along with the sublet cleaning of the CAC, using the CAC as the causal part number.

Fault Codes 2776 and 1861 (Ref Cummins TSB101120)

Mack and Volvo

Tip to attach a jobcard to eService

PTT 1.12

Mack and Volvo

Any time you perform testing within PTT, a new job card should be made. After a fault code read out and any testing has been performed if you wish to attach the job card to an E-service case you will need to finalize the job card. Once you have finalized the job card click onto the job card tab at the top of the PTT screen, in the drop down menu click on Export. Click on to highlight the report you wish to export, next check the box named Export to HTML then click the Export tab. A box will appear and you will have the choice where you want to save the file, it is suggested to save the file in your (C) drive. You can name the file anything you wish. When you go into your E-service case and click on attachments you will be asked to find the file you wish to attach, simply go into your (c) drive and find the Jobcards file, open the file and click on the jobcard you wish to attach. If your file is too large to attach to the case then you will need to convert the file to a compressed zip file then you will be able to attach the file. To convert a file to a compressed zip file simply left click (one time) on the file to highlight it, and then right click. In the Drop down menu select (send to), then select Compressed (zipped) File. A compressed version of the file will be created allowing you to attach it to the E-service case.

ECM ACM Software Service Programs POSTPONED

SP 284-042, SP 284047, PI0826, PI0831

Mack and Volvo

Logics for the PCJ (Piston Cooling Jet) are currently being updated. The update affects 11L & 13L engine platforms for the US13 product. Anticipated time of re-release 1/15/2014

10 January 15, 2014

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New Item Description Reference Comment Analysis of warranty claim data and Tech Support cases has shown that unnecessary diagnostic time is being required for most fault codes related to sensor replacements. Review SNM13-044 and SNV13-043 for the affected DTCs for both US07 and US10 Emissions. Changes to Guided Diagnostics are in process to reflect this approach. (both documents in TDP/service/news and info) TDP/service/tech support/PTT icon for FAQs on TT1, TT2, videos, submitting Concern Reports

EPA-2007/2010 11-13-16 liter DTCs

Active Fault Codes

Mack and Volvo

Premium Tech Tool FAQs

Frequently Asked Questions

Mack and Volvo

11 January 15, 2014