MRU Series

MRU Series
®
Mack MRU Series
Mack TerraPro Series
(MRU Series)
®
© Mack Trucks, Inc. 2010
Printed in U.S.A.
21394655
21394655
TM
Mack TerraPro Series
(MRU Series)
®
21394655
April 2010
TM
Foreword
This manual contains information concerning the operation and
function of the Mack Link System. The information in this manual
applies to vehicles built 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
Mack Trucks, Inc. 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: PV776-21394655
©2010 Mack Trucks 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.
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 .......................................................................12
ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY.............14
FEDERAL EMISSION REQUIREMENTS............................................................15
EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA..................15
Emissions Control System Warranty .......................................................................17
SERVICE LITERATURE ............................................................................................21
– MACK Class 8 –Components Service Manual ....................................................21
– Class 8 – Custom Collated Service Manual on CD ..............................................21
CUSTOMER SERVICE ..............................................................................................22
Call 1-800-866-1177 for MACK OneCall™ ...........................................................22
Questions and Complaints .......................................................................................22
Addresses .................................................................................................................23
Additional Assistance ..............................................................................................23
REPORTING SAFETY DEFECTS.............................................................................25
United States ............................................................................................................25
Canada......................................................................................................................25
Mexico .....................................................................................................................25
EVENT DATA RECORDING DEVICES...................................................................26
SAFETY INFORMATION ...........................................................................................27
SAFETY STATEMENT ..............................................................................................27
CERTIFICATION LABELS........................................................................................29
Safety Certification Label ........................................................................................29
ADVISORY LABELS .................................................................................................31
Advisory Label Locations (On Vehicle) ..................................................................31
TRUCK-TRACTOR CONSPICUITY.........................................................................39
CAB ENTRY/EXIT .....................................................................................................40
Three-Limb Contact.................................................................................................40
Driver Side ...............................................................................................................42
Passenger Side .........................................................................................................44
Deck Plate Access....................................................................................................46
SAFETY TIPS FOR COLD WEATHER OPERATION .............................................48
Driver Visibility .......................................................................................................48
Cab Door Seals and Key Locks ...............................................................................49
Outside Mirror Heater..............................................................................................49
Air Horn Snow Shield..............................................................................................50
Emergency Reflector Kit..........................................................................................50
Fire Extinguisher (Optional) ....................................................................................50
INSTRUMENTS AND CONTROLS ...........................................................................51
CAB INTERIOR..........................................................................................................51
INSTRUMENT PANEL ..............................................................................................52
Tell-Tales..................................................................................................................52
Panel Arrangement...................................................................................................52
INSTRUMENT PANEL GAUGE LAYOUT ..............................................................53
Panel A.....................................................................................................................53
Panel B .....................................................................................................................54
Panel C .....................................................................................................................55
Panel D.....................................................................................................................56
Panel E .....................................................................................................................57
Regeneration ............................................................................................................63
Parked Regeneration (If Needed).............................................................................65
DPF INHIBIT ROAD SPEED LIMITING (RSL)...................................................67
Function of Optional Switches.................................................................................71
CAB CLIMATE CONTROL .......................................................................................74
LIGHT CONTROL PANEL ........................................................................................75
STEERING COLUMN................................................................................................76
Electrical Switch ......................................................................................................76
FLOOR PEDALS ........................................................................................................77
MISCELLANEOUS CONTROLS ..............................................................................78
Dome Light ..............................................................................................................78
Air Horn ...................................................................................................................79
Fresh Air Vent ..........................................................................................................79
Accessory Power Outlets .........................................................................................79
PRE-TRIP INSPECTION AND DAILY MAINTENANCE......................................81
PRE-TRIP ....................................................................................................................81
Pre-Trip Inspection Quick List ................................................................................81
OPERATION..................................................................................................................94
.....................................................................................................................................94
New Vehicle Break-In..............................................................................................94
WINDSHIELD WASHER RESERVOIR ....................................................................96
CAB TILT OPERATION.............................................................................................97
Tilting the Cab .........................................................................................................98
Lowering the Cab...................................................................................................100
Bleeding the Cab Tilt System ................................................................................101
HOSE TENDERS ......................................................................................................102
DOORS ......................................................................................................................103
Standard Door Panel ..............................................................................................103
Opening the Cab Door ...........................................................................................104
Locking the Cab Door............................................................................................104
REMOTE KEYLESS ENTRY — (OPTIONAL)......................................................105
Transmitter Operations ..........................................................................................106
Battery Replacement..............................................................................................106
SEAT BELTS .............................................................................................................110
Seat Belt Operation ................................................................................................110
Fastening Seat Belt ................................................................................................110
Komfort® Latch System........................................................................................113
SEAT ADJUSTMENT AND RECLINE (IF EQUIPPED)........................................115
MACK ENGINE INFORMATION ...........................................................................115
Precautions and Warnings......................................................................................115
Engine Model Designations...................................................................................117
CRUISE CONTROL OPERATION ..........................................................................118
Speed Control Switches .........................................................................................118
Disengaging Cruise Control...................................................................................119
MACK POWERLEASH™ ENGINE BRAKE (IF EQUIPPED)..............................120
Engine Brake Switch..............................................................................................120
How the Engine Brake is Activated.......................................................................121
Cruise Control with the MACK PowerLeash™ Engine Brake .............................121
ON THE ROAD WITH THE MACK POWERLEASH™ ENGINE BRAKE .........123
Over Flat Terrain....................................................................................................123
Descending a Grade ...............................................................................................124
On Slippery Road Surfaces....................................................................................126
BRAKE OPERATION...............................................................................................128
Air Brake System...................................................................................................128
Automatic Slack Adjusters ....................................................................................129
Parking Brake System............................................................................................129
Parking Brake Operation........................................................................................130
Parking ...................................................................................................................130
Anti-Lock Brake System (ABS) ............................................................................130
Automatic Traction Control (ATC) (If Equipped) .................................................134
GOOD DRIVING HABITS.......................................................................................136
Weight Ratings.......................................................................................................136
Instruments.............................................................................................................136
Shutting Down the Engine .....................................................................................136
General Observation ..............................................................................................136
STARTING THE VEHICLE .....................................................................................137
General Information...............................................................................................137
Push Button Starters...............................................................................................137
Air Starters .............................................................................................................138
Engine Warm-Up ...................................................................................................140
Engine Idling..........................................................................................................141
Shutting Down the Engine .....................................................................................141
COLD WEATHER OPERATION .............................................................................144
Cold Weather Starting Tips....................................................................................144
Engine Block Heaters ............................................................................................145
Winterfronts ...........................................................................................................146
COUPLING A TRAILER..........................................................................................148
UNCOUPLING A TRAILER....................................................................................150
MOVING THE VEHICLE — GENERAL INFORMATION ...................................152
Braking...................................................................................................................152
Shifting...................................................................................................................152
Engine Temperature ...............................................................................................153
Clutch (If Equipped) ..............................................................................................153
POWER TAKE-OFF (PTO) OPERATION ...............................................................157
PTO Precautions ....................................................................................................157
PTO Classification .................................................................................................158
Side-Mounted PTO Locations ...............................................................................158
PTO Operating Procedures ....................................................................................158
TRANSMISSION SHIFTING INSTRUCTIONS.....................................................159
Shifting Instructions for Allison Automatic Transmissions ..................................159
MACK T306G Shifting Instructions .....................................................................159
MACK TM308 Shifting Instructions.....................................................................160
MACK TM308M Shifting Instructions .................................................................163
MACK TM309 Shifting Instructions.....................................................................165
MACK TM309M Shifting Instructions .................................................................167
MACK T309, T309L and T309LR Shifting Instructions ......................................169
MACK T310 Shifting Instructions ........................................................................173
MACK T310M, T310ME and T310MLR Shifting Instructions ...........................176
MACK T313-T313L-T313LR Shifting Instructions .............................................180
MACK T31321, T313L21 and T313LR21 Shifting Instructions ..........................185
MACK T318, T318L and T318LR Shifting Instructions ......................................189
MACK T31821, T318L21 and T318LR21 Shifting Instructions ..........................195
AXLES.......................................................................................................................201
Rear Axles Other Than MACK .............................................................................201
MACK Rear Axles.................................................................................................201
Engaging the Power Divider Lockout....................................................................202
Mack, US10 Emissions Solution .................................................................................204
DIESEL PARTICULATE FILTERS .........................................................................204
Extended Idling and Aftertreatment System Conditioning ...................................206
Exhaust Aftertreatment System .................................................................................208
Safety Information .................................................................................................209
Exhaust Aftertreatment System Components and ................................................210
Selective Catalytic Reduction (SCR) ....................................................................210
Diesel Exhaust Fluid (DEF)...................................................................................212
Aftertreatment Diesel Particulate Filter (DPF) ......................................................214
Aftertreatment Control Module (ACM).................................................................215
Aftertreatment DPF Regeneration ........................................................................215
Driver Warnings and On Board Diagnostics (OBD) .............................................217
On Board Diagnostics (OBD)................................................................................217
Instrument Cluster..................................................................................................218
Malfunction Indicator Lamp (MIL) .......................................................................219
Aftertreatment DEF Tank Level - Driver Warning & Inducement........................220
Aftertreatment DEF Quality - Driver Warning & Inducement ..............................221
Misfilling Diesel or Aftertreatment DEF Tanks.....................................................222
SCR Tampering - Driver Warning & Inducement .................................................223
Warranty and Maintenance ....................................................................................224
Exhaust Aftertreatment System Maintenance........................................................224
Engine Maintenance Intervals................................................................................224
MAINTENANCE AND LUBRICATION..................................................................225
MAINTENANCE INTRODUCTION .......................................................................225
TURBOCHARGER...................................................................................................225
CLEANING YOUR VEHICLE.................................................................................226
Exterior Washing ...................................................................................................226
Cab and Hood ........................................................................................................228
Chassis ...................................................................................................................228
Cab Interior ............................................................................................................229
Waxing ...................................................................................................................229
Polishing ................................................................................................................229
Winter Warnings ....................................................................................................229
TOWING ...................................................................................................................230
ENGINE OIL LEVEL CHECK.................................................................................231
Power Steering Reservoir ......................................................................................232
FUEL TANK..............................................................................................................234
Fuel Tank Cap ........................................................................................................234
FUELING ..................................................................................................................235
BioDiesel................................................................................................................236
B5 Approval For Mack US10 Certified Products ..................................................236
COOLING SYSTEM.................................................................................................238
Coolant Level Check..............................................................................................238
Draining the Cooling System.................................................................................239
Refilling the Cooling System .................................................................................239
Protecting the Cooling System ..............................................................................240
Cooling System Maintenance ................................................................................241
Accessory Drive Belt Routing ...............................................................................242
Accessory Drive Belt Routing ...............................................................................242
HEADLIGHTS ..........................................................................................................244
Bulb Replacement..................................................................................................244
WHEELS ...................................................................................................................244
Wheel Inspection ...................................................................................................244
Tires .......................................................................................................................245
BATTERY..................................................................................................................248
Jump-Starting Engine.............................................................................................248
ELECTRICAL ...........................................................................................................249
Circuit Breaker and Relay Panels ..........................................................................249
Electrical Grease ....................................................................................................253
METRIC CONVERSIONS.........................................................................................256
METRIC CONVERSIONS .......................................................................................256
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
type on a gray background with a black
border.
CAUTION
Caution indicates an unsafe practice that
could result in damage to the product.
A caution advisory is in black type on a
white background with a black border.
Note: Note indicates a procedure, practice,
or condition that must be followed in order
for the vehicle or component to function
in the manner intended.
INTRODUCTION 1
TO THE OWNER
In Appreciation
Thank you for buying a MACK® vehicle. With proper care and maintenance,
your new Mack® TerraPro™ MRU model will help you gain a competitive
edge with its fuel-efficient drivetrain combinations, low maintenance,
extended service intervals and, eventually, good resale value.
The Mack® TerraPro™ MRU 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
the life of the vehicle. Only trained and informed drivers should operate this vehicle.
We, at Mack Trucks, Inc., hope that you will be happy with your new Mack®
TerraPro™ 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.
2 INTRODUCTION
About This Handbook
This handbook is referred to as the Mack® TerraPro™ Series Operator’s
Handbook. It covers all Mack® TerraPro™ models. 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 225. For further
information, refer to the Maintenance and Lubrication Manual. Other important
information can be found in the Emission Control Systems for MACK Diesel Engine
Manual.
INTRODUCTION 3
THE VEHICLE
Basic Configuration
The Mack® TerraPro™ MRU model has a low-entry, cab-forward-style
operators compartment. Low profile and excellent visibility make this model
popular throughout the refuse-hauling, construction and firefighting industries.
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.
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.
C0029554
The VIN label is located on the inside door frame below the driver seat.
C0028941
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
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"
INTRODUCTION 7
Clean Idle Engines
The California Air Resources Board (ARB) requires that 2008 and later 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 lower portion of the driver’s side door on cab-over
models (MRU).
W2056289
Clean Idle Engine Label
8 INTRODUCTION
Transmission Identification
The MACK T300 Series transmission serial number is located on the rear
left side of the main case.
C0028947
The Allison RDS and EVS transmission identification plate is located on the
rear right side of the main case, near the lower end.
C0029555
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.
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
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
INTRODUCTION 11
WARRANTY INFORMATION
This chassis is equipped with a US 2010 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 warranty.
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 engine vendor’s publication
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
Mack Trucks, Inc. or its nearest authorized
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.
•
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.
Damage resulting from accident, acts
of nature or other events beyond the
control of Mack Trucks, Inc.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR
OTHERWISE, EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED
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 Federal code of emission regulations.
•
1 Turbocharger Assembly
•
VGT Actuator
2 Charge Air Cooler
•
CAC Pipes (Air inlet to/from CAC)
CAC Hoses
3 Engine Control Module (ECM)
4
Injectors
INTRODUCTION 13
5 Engine and Vehicle Wire harness (
repair to circuits related to Emissions
Warrantable Components )
6 Exhaust Gas Recirculation (EGR)
Mixer
•
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
7 EGR Cooler
8 EGR Valve and EGR Valve Control
9 EGR Pipes - Engine Exhaust Manifold
to EGR Cooler
10 EGR Pipes - EGR Cooler to Inlet
Manifold
B. Thermal Regeneration Unit (TRU)
•
Aftertreatment DPF Combustion
Air Control Valve
12 Crankcase Separator
•
13 Crankcase Tubing and Hoses before
Separator
Aftertreatment DPF Combustion
Air Valve
•
14 Aftertreatment Wiring Harness
Aftertreatment DPF Atomization
Module
•
•
Aftertreatment DPF Ignition Coil
•
Aftertreatment DPF Ignition
Electrode
Nozzle
11 Crankcase Breather
15 After treatment Control Module (ACM)
16 Aftertreatment Diesel Particulate Filter
(DPF) Assembly
A. Aftertreatment DPF Assembly
with Aftertreatment Diesel Oxidation
Catalyst (DOC)
Aftertreatment DPF Fuel Control
Valve
•
•
Aftertreatment Doser
•
•
Diffuser Pipe (Aftertreatment Fuel
Doser Mounting)
•
•
Fuel lines to Aftertreatment Fuel
Doser
Aftertreatment DPF Intake
Temperature Sensor
•
•
•
•
Aftertreatment Fuel Shutoff Valve
Aftertreatment DPF Outlet
Temperature Sensor
•
Aftertreatment DPF Spark Assist
Flame Temperature Sensor
•
Aftertreatment DPF Differential
Pressure Sensor
Aftertreatment Fuel Pressure Sensor
Discharge Recirculation Valve
(DRV) (Heat Mode)
•
Discharge Recirculation Valve
(DRV) Solenoid
•
Engine Turbocharger Compressor
Bypass Actuator (Heat Mode)
•
Engine Turbocharger Compressor
Bypass Actuator Solenoid
•
Engine Exhaust Gas Temperature
(EGT) Sensor
Engine Exhaust Gas Temperature
(EGT) Sensor
17 Sensors:
•
•
•
•
•
•
Crankshaft Position (CKP)
Camshaft Position (CMP)
Engine Coolant Temperature (ECT)
Intake Manifold Air Temperature
Intake Manifold Pressure (IMP)
EGR Temperature
14 INTRODUCTION
•
•
•
•
Aftertreatment Outlet NOx
Aftertreatment Intake NOx
EGR Differential Pressure
Ambient Air Temperature (AAT)
18 SCR
•
Aftertreatment Selective Catalytic
Reduction (SCR) Catalyst
•
Aftertreatment Diesel Exhaust Fluid
(DEF) Pump
•
•
•
•
•
Aftertreatment DEF Tank Heater
•
Aftertreatment DEF Tank
Temperature Sensor
•
•
Aftertreatment DEF Level Sensor
Aftertreatment DEF Tank Heater
Valve
Aftertreatment DEF Heated Lines
•
Aftertreatment DEF Dosing
Absolute Pressure Sensor
•
19. Instrument Cluster (Repair of
microprocessor , OBD MIL, Real Time
Clock, Aftertreatment DEF Tank Gauge
and, Aftertreatment DEF Tank Low Level
Indicator)
Aftertreatment DEF Return
Valve
20. Exhaust Gas Piping (from
Turbocharger to Aftertreatment System )
Aftertreatment DEF Dosing Valve
21. Data Link Connector (DLC)
Aftertreatment DEF Tank
Aftertreatment DEF Tank
Heater/Sender
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
nozzle at the regular maintenance intervals
is considered normal maintenance and not
covered by the emission warranty.
Note: In response to customer requests,
Mack Trucks, Inc. may build vehicles with
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.
INTRODUCTION 15
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:
1 Any person prior to its sale and delivery
to the ultimate purchaser, or
2 Any manufacturer or distributor after
its sale and delivery to the ultimate
purchaser, or
trading motor vehicles or motor vehicle
engines following its sale and delivery
to the ultimate purchaser, or
4 Any 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 .
3 Any person engaged in the business of
repairing, servicing, selling, leasing, or
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
on your engine for the period of time listed
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.
16 INTRODUCTION
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
found to be defective upon examination by
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
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.
INTRODUCTION 17
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR
OTHERWISE, EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED
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.
1 Turbocharger Assembly
•
VGT Actuator
2 Charge Air Cooler
•
•
Aftertreatment Doser
Diffuser Pipe (Aftertreatment Fuel
Doser Mounting)
•
Fuel lines to Aftertreatment Fuel
Doser
•
•
•
Aftertreatment Fuel Shutoff Valve
•
6 Exhaust Gas Recirculation (EGR)
Mixer
Engine Turbocharger Compressor
Bypass Actuator Solenoid
•
7 EGR Cooler
Engine Exhaust Gas Temperature
(EGT) Sensor
•
Aftertreatment DPF Intake
Temperature Sensor
9 EGR Pipes - Engine Exhaust Manifold
to EGR Cooler
•
Aftertreatment DPF Outlet
Temperature Sensor
10 EGR Pipes - EGR Cooler to Inlet
Manifold
•
Aftertreatment DPF Differential
Pressure Sensor
11 Crankcase Breather
•
Aftertreament Doser Air Supply
Regulator (if applicable), Supply
Lines, and Fittings
•
•
CAC Pipes (Air inlet to/from CAC)
CAC Hoses
3 Engine Control Module (ECM)
4
Injectors
5 Engine and Vehicle Wire harness (
repair to circuits related to Emissions
Warrantable Components )
8 EGR Valve and EGR Valve Control
12 Crankcase Separator
Aftertreatment Fuel Pressure Sensor
Engine Turbocharger Compressor
Bypass Actuator (Heat Mode)
13 Crankcase Tubing and Hoses before
Separator
B. Thermal Regeneration Unit (TRU)
14 Aftertreatment Wiring Harness
•
Aftertreatment DPF Air Shutoff
Valve
•
Aftertreatment DPF Combustion
Air Valve
•
Aftertreatment DPF Atomization
Module
•
Aftertreatment DPF Ignition Coil
15 After treatment Control Module (ACM)
16 Aftertreatment Diesel Particulate Filter
(DPF) Assembly
A. Aftertreatment DPF Assembly
with Aftertreatment Diesel Oxidation
Catalyst (DOC)
18 INTRODUCTION
•
Aftertreatment DPF Fuel Control
Valve
•
Aftertreatment Selective Catalytic
Reduction (SCR) Catalyst
•
Aftertreatment DPF Ignition
Electrode
•
Aftertreatment Diesel Exhaust Fluid
(DEF) Pump
•
•
Nozzle
•
Engine Exhaust Gas Temperature
(EGT) Sensor
Aftertreatment DEF Dosing
Absolute Pressure Sensor
•
•
Aftertreatment DPF Intake
Temperature Sensor
Aftertreatment DEF Return
Valve
•
Aftertreatment DPF Outlet
Temperature Sensor
•
Aftertreatment DPF Spark Assist
Flame Temperature Sensor
•
Aftertreatment DPF Differential
Pressure Sensor
17 Sensors:
•
•
•
•
•
•
•
•
•
•
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)
18 SCR
•
•
•
Aftertreatment DEF Dosing Valve
Aftertreatment DEF Tank
Aftertreatment DEF Tank
Heater/Sender
•
•
Aftertreatment DEF Tank Heater
•
Aftertreatment DEF Tank
Temperature Sensor
•
•
Aftertreatment DEF Level Sensor
Aftertreatment DEF Tank Heater
Valve
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)
INTRODUCTION 19
ENGINE GASEOUS EMISSION CONTROL SYSTEMS
WARRANTY — Continued
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
nozzle at the regular maintenance intervals
is considered normal maintenance and not
covered by the emission warranty.
Note: In response to customer requests,
Mack Trucks, Inc. may build vehicles with
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.
CAUTION
Any unauthorized adjustments to the
emission control components can cause
severe damage to the engine.
1.Repairs by MACK Dealers,
Sub-Dealers and Service Dealers
Repairs covered by the California
Emission Control Systems Warranty will
be performed by any authorized MACK
repair facility at his place of business with
no charge for parts and labor (including
diagnosis), using MACK parts for any part
of the emission control systems covered
by this warranty and found defective.
2.In an Emergency
In an emergency, where an authorized
MACK facility is not available, repairs
may be performed at any available service
establishment, or by the owner, using any
replacement part, within the limitations
of paragraphs 3 and 4 in this section. An
emergency condition exists under this
section if, after 30 days, repairs have
not been completed or parts are not yet
available. MACK will reimburse the
owner for such repairs that are covered
under this warranty, including diagnosis,
not to exceed MACK’s suggested retail
price for parts replaced and labor charges
based on MACK’s recommended time
allowance and geographically appropriate
hourly labor rate. Replaced parts and paid
invoices must be presented at a MACK
facility as a condition of reimbursement for
emergency repairs performed elsewhere.
CAUTION
In the event that damage results from
unauthorized adjustments to any
emission control system components,
as evidenced by settings other than as
specified, or broken fastener seals, the
cost of repairing such damage WILL
NOT BE COVERED under warranty
3. Repairs by Non-MACK Facilities
Owners may elect to have maintenance,
replacement, or repair of emission control
systems performed by any repair facility,
and may elect to use parts other than
MACK parts without invalidating the
warranty on other components, but the
cost of such service or parts will not be
covered by MACK under its warranty.
4. Use of Non-MACK Parts
Use of replacement parts which are not the
equivalent of MACK parts may impair the
effectiveness of emission control systems.
If other than MACK parts are used, the
20 INTRODUCTION
owner should obtain assurances that such
parts are warranted by their manufacturer
to be the equivalent of MACK parts
in performance and durability. MACK
assumes no liability under this warranty
with respect to parts other than MACK
parts; however, the use of non-MACK
parts does not invalidate the warranty on
other components unless non-MACK parts
cause damage to warranted parts.
5. Maintenance and Maintenance
Records
The vehicle owner is responsible for the
performance of all required maintenance
specified in this manual. MACK will not
deny a warranty claim solely because there
is no record of maintenance; however,
MACK may deny a warranty claim if
failure to perform required maintenance
results in the failure of a warranted part.
Receipts or other records covering the
performance of scheduled maintenance
should be retained to answer questions
that may arise concerning maintenance.
Maintenance records should be transferred
to subsequent owners if the vehicle is sold.
6. Items Not Covered by the Emission
Control Systems Warranty
•
Malfunctions caused by misuse,
improper adjustments, modification,
alteration, tampering, disconnection,
improper or inadequate maintenance
and use of improper diesel fuel.
•
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.
7. Customer Assistance
MACK wishes to assure that the California
Emission Control Systems Warranty is
properly administered. In the event that
owners do not receive the warranty service
to which they believe they are entitled
under the California Emission Control
Systems Warranty, they should contact
the nearest MACK Regional Office for
assistance. The address and telephone
number for each Regional Office are
in the MACK Directory of Sales, Parts
and Service Centers. Owners in need
of additional assistance or information
concerning the California Emission
Control Systems Warranty may also
contact:
Mack Trucks, Inc.
Warranty Activities
P.O. Box 26259
Greensboro, NC 27402
INTRODUCTION 21
SERVICE LITERATURE
The MACK Service Publications department offers a variety of service literature
(including individual service manuals) that can be ordered through any MACK
dealer or on the Mack Trucks, Inc. website at www.macktrucks.com.
Note: Mack Trucks, Inc. would like to emphasize the importance of proper service
and maintenance procedures. Service, repair and replacements must be performed by
certified, licensed mechanics in accordance with MACK standards.
– MACK Class 8 –Components Service Manual
This multi-binder set contains service information covering all MACK
components (i.e., engines, transmissions, front and rear axles, cabs, fuel
systems, electrical systems).
Note: If your vehicle contains a number of non-MACK (vendor) components, the
Class 8 – Custom Collated Service Manual might be more appropriate.
– Class 8 – Custom Collated Service Manual on CD
This tailor-made set provides complete service information for all components
in the specified vehicle (including both MACK and vendor service manuals).
When ordering a Class 8 – Custom Collated Service Manual or Class 8 –
Custom Collated Service Manual on CD , be sure to include the complete
Model-Serial number and General Sales Order (GSO) number.
22 INTRODUCTION
CUSTOMER SERVICE
Call 1-800-866-1177 for MACK OneCall™
The OneCall customer support system is a toll-free nationwide hotline that
operates 24 hours a day, seven days a week, including holidays. If you break
down on the road, simply call 1-800-866-1177. There is a staff of trained,
experienced technicians ready to help. They can help troubleshoot a problem
to get you back on the road, arrange to send roadside assistance or arrange
for towing to the nearest MACK dealership.
OneCall provides personalized service. The person who initially takes your
call will be the same person who sees that your situation is resolved quickly
and to your satisfaction. If a follow-up call is necessary, the same familiar
voice will be on the other end of the line.
OneCall technicians can also help you plan ahead to keep your operation
running efficiently by scheduling routine maintenance and lubrication service,
or by locating the nearest MACK dealership.
Questions and Complaints
Your satisfaction is our most important concern.
If questions or complaints arise, first discuss the matter with the service
manager at the MACK facility involved. If you are not satisfied with the
service manager’s response, contact the branch manager, principal or general
manager of the distributorship. If assistance is required at a service dealer,
contact the owner of the establishment.
If, for any reason, you need further assistance after dealing with the personnel
at a MACK subsidiary or distributor, contact the regional service manager at
the nearest MACK regional service office. The regional service manager has
the responsibility and the authority to recommend action in most cases and
(with the aid of relevant district service personnel) will make every effort to
conduct a fair review of the situation.
INTRODUCTION 23
Addresses
The addresses, telephone and fax numbers of the Mack Trucks, Inc. regional
offices are:
United States
Northeast Region – 7900 National Service Road, Mail: P.O. Box 26259,
Greensboro NC 27402 , TEL: (336) 291-9001
Southeast Region – 6768 Southlake Parkway, Morrow, GA 30260, TEL:
(770) 960-0511, FAX: (770) 960-0593
Central Region –900 S. Frontage Rd., Suite 100, Woodridge, IL 60517, TEL:
(630) 910-3330, FAX: (630) 910-3331
Southwestern and Western Regions – 5605 N. MacArthur Blvd., #550,
Mail: P.O. Box 165408, Irving, TX 75016-5408, TEL: (972) 518-1614, FAX:
(972) 550-0389
Canada
Executive Office – Mack Canada, Inc., 5600A Cancross Court, Mississauga,
ON L5R 3E9, TEL: (905) 366-3400, FAX: (905) 366-0165
Australia
Mack Trucks Australia Pty. Ltd., CNR Archerfield and Boundary Roads, Mail:
P.O. Box 364, Richlands, QLD 4077, Australia, TEL: 61-7-3853-3333, FAX:
61-7-3853-3392
International
7900 National Service Road, Mail: P.O. Box 26259, Greensboro NC 27402 ,
TEL: (336) 291-9001
Additional Assistance
If additional assistance is required, Mack Trucks, Inc. maintains a Customer
Service Department (staffed by experienced personnel) to aid customers who
need information or assistance not provided at the local or regional level.
The Customer Service Department phone number is (610) 709-3961.
When contacting the regional service offices or Customer Service Department,
provide the following information:
24 INTRODUCTION
•
•
•
•
•
•
•
•
Vehicle Identification Number (VIN) — This 17-digit number is typically located
on a label on the driver-side door latch post and behind the front axle on the
right, front frame rail.
Model and year of the vehicle
Date that the vehicle was purchased and put into service
Date(s) and mileage of repair(s)
Dealer that sold and/or serviced the vehicle
Description of unresolved service complaint or inquiry
Summary of action taken to date (by the dealer and the regional service office)
Names of individuals (if known) contacted at the dealer and the Mack Trucks, Inc.
regional service office.
INTRODUCTION 25
REPORTING SAFETY DEFECTS
United States
If you believe that your vehicle has a defect which could cause a crash, injury
or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA), in addition to notifying Mack Trucks, Inc.
If NHTSA receives similar complaints, it may open an investigation and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your distributor, or Mack Trucks, Inc.
To contact NHTSA, either call the U.S. Government’s Vehicle Safety
Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to
http://www.NHTSA.gov; or write to: Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590.
You can also obtain other information about motor vehicle safety from the
Vehicle Safety Hotline.
Canada
Canadian customers who wish to report a safety-related defect to Transport
Canada — Defect Investigations and Recalls, may telephone the toll free
hotline at 1-800-333-0510, or contact Transport Canada by mail at Transport
Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa ON K1A
0N5. For additional road safety information, please visit the Road Safety
website at http://www.tc.gc.ca/roadsafety/menu.htm.
Mexico
Mack Trucks, Inc. de Mexico, S.A. de C.V. should be informed immediately
if you believe the vehicle has a defect that could cause a vehicle
accident, injury or death. Contact Mack Trucks, Inc. de Mexico by calling
011-52-55-50-81-68-50 or by writing to: MackTrucks, Inc. de Mexico, S.A. de
C.V., Prol. Paseo de la Reforma 600, 1er. Piso — 121, Col. Santa Fe Pena
Blanca, C.P. 01210, Mexico, D.F. Within Mexico, call 01 (800) 90 94 900.
26 INTRODUCTION
EVENT DATA RECORDING DEVICES
Your MACK vehicle is equipped with a device generally referred to as an
"event data recorder" or "EDR." Please note that while the term "event data
recorder" is typically used throughout the motor vehicle industry, not every
EDR is the same; i.e., they do not all record the same data elements. The
EDR on your MACK vehicle records vehicle speed, engine rpm, time and
date, plus a variety of pedal and switch positions, both before and after an
"event." Sudden vehicle deceleration or the occurrence of certain other vehicle
operational characteristics will define (trigger) an "event."
Optional equipment available for your MACK vehicle, such as the Eaton®
VORAD® Collision Warning System, may also provide event data recording
features.
If you have a question about your EDR, please contact your MACK dealer or
regional service office.
SAFETY INFORMATION 27
SAFETY STATEMENT
Mack Trucks, Inc. cannot anticipate every possible occurrence which may
involve a potential hazard. An accident can be avoided by recognizing
potentially hazardous situations before a dangerous situation occurs.
Correctly performed service procedures are critical for technician safety and
safe, reliable operation of the vehicle.
DANGER
Do not operate the engine in an enclosed area. All internal combustion engines
give off various fumes and gases while running. Inhalation of exhaust fumes can
cause death.
DANGER
Do not sit in a parked vehicle for any extended amount of time with the engine
running if there are leaks in the exhaust system. Exhaust fumes could leak into the
cab area and death can result. On a regular basis inspect the exhaust system for
leaks and repair any leakage.
DANGER
Driver attitude is the most important part of any effective vehicle safety system.
Mack Trucks, Inc. strongly encourages all drivers and passengers to use their seat
belts, drive defensively, remain alert and respect the speed limits. Many accidents
can also be avoided through regular vehicle maintenance.
DANGER
Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts,
driveshafts and other related rotating assemblies, can be very dangerous. Do not
service engine-driven components unless the engine is shut down. Always keep
body parts and loose clothing out of range of these powerful components to prevent
serious personal injury. Be aware of PTO engagement or nonengagement status.
Always disengage the PTO when not in use.
28 SAFETY INFORMATION
WARNING
Certain everyday procedures such as washing the vehicle and cleaning the
windshield can also be hazardous because of the vehicle’s height. Mack Trucks,
Inc. does NOT recommend climbing up on the vehicle to perform these operations.
Instead, stand on the ground and use brushes and squeegees mounted on extension
poles. When better access is necessary (for instance, when washing the cab roof),
use sturdy ladders held in place by someone on the ground.
WARNING
Secure loose objects. Loose objects in the cab or sleeper can be dangerous in a
sudden stop or on bad roads. Secure any appliance added to the vehicle, such as a
refrigerator or a radio.
WARNING
Keep clear of fan when engine is running. Fan may start to rotate at high speed
without warning.
SAFETY INFORMATION 29
CERTIFICATION LABELS
Safety Certification Label
National Highway Traffic Safety Administration (NHTSA) regulations require
affixing a certification label to all vehicles.
NHTSA regulations also require that the certification label be affixed to either
the hinge pillar, door latch post or the door edge that meets the door latch
post next to the driver seat. If none of these locations are practical, it may be
attached to the left side of the instrument panel or to an inward facing surface
of the driver-side door.
In compliance with NHTSA regulations, your Mack® vehicle has a safety
certification label affixed in one of the NHTSA locations listed above. This
label may be either an Incomplete Vehicle and/or Completed Vehicle label.
Both labels are described below.
Incomplete Vehicles
C0028955
A chassis-cab is an incomplete vehicle with a completed occupant
compartment that requires the addition of cargo-carrying, work-performing or
load-bearing components to perform its intended functions.
The chassis-cab manufacturer must affix a label to the incomplete vehicle in
one of the NHTSA locations listed above. This label provides the chassis-cab
date of manufacture, VIN and vehicle certification information.
30 SAFETY INFORMATION
Completed Vehicles
In addition to the label supplied by Mack Trucks, Inc. as the chassis-cab
manufacturer, a Completed Vehicle certification label, supplied by the body
manufacturer, is affixed in the same general location. This label provides
information pertaining to Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR), tire and rim information, etc.
On MACK-completed vehicles, this label contains the date of manufacture,
VIN, GVWR, GAWR, and tire and rim data. It is found in one of the NHTSA
locations listed above.
C0028956
SAFETY INFORMATION 31
ADVISORY LABELS
Throughout this book you will find paragraphs labeled Danger, Warning,
Caution, Note and Service Hint. Danger, Caution and Warning labels are
also found in various locations on the vehicle to alert drivers, operators and
service technicians to situations which can cause personal injury or equipment
damage. The labels shown are applicable to the Mack® TerraPro™ MRU
model chassis at the time of publication and are representative of what can be
typically found on a Mack® TerraPro™ MRU. (Your vehicle may not contain all
of the labels illustrated in this handbook.) These labels are for your benefit.
Please look through this section and note the labels, their locations and what
they explain. Be sure to replace any label that is damaged.
Advisory Label Locations (On Vehicle)
Labels Found on Chassis
C0029676
32 SAFETY INFORMATION
C0029677
SAFETY INFORMATION 33
C0029678
34 SAFETY INFORMATION
Labels Found on Driver-Side Sun Visor
C0029679
SAFETY INFORMATION 35
Labels Found on Instrument Panel
C0029017
Labels Found on Windshield
C0029018
Note: Label to be removed upon delivery to the end user. Refer to “BRAKE
OPERATION”, page 128 in the OPERATION section for additional information.
36 SAFETY INFORMATION
Eaton Controlled Traction Differential Label
Labels Found on Fuel Tank
C0029020
C0029021
SAFETY INFORMATION 37
PTO Safety Label (If Equipped)
C0029680
If the chassis is equipped with a PTO, the safety label is located on the
instrument panel, on the bottom of gauge Panel E.
For detailed instructions on transmission and PTO shift sequences, refer to
the OPERATION section of this handbook beginning on “POWER TAKE-OFF
(PTO) OPERATION”, page 157.
38 SAFETY INFORMATION
Back Up Alarm (Optional)
Your chassis may be equipped with an optional back up alarm. If so, the
following label will appear inside the cab.
C0029681
SAFETY INFORMATION 39
TRUCK-TRACTOR CONSPICUITY
To make the vehicle more conspicuous when approached from the rear (in
times when visibility is reduced), all truck/tractors built on or after July 1, 1997
have reflective devices applied on the rear of the cab and on the mudflaps or
mudflap hanger brackets if mudflaps or mudflap hanger brackets are supplied
from the factory. If mudflaps or mudflap hanger brackets are not supplied from
the factory, reflective devices will be applied on the rear, lower portion of the
cab. Refer to the illustration. Locations of these reflective devices may vary
from this illustration, depending on the cab model and/or equipment added
to the rear of the cab.
C0029023
1. White Reflective Devices Back of
Cab
3. Red and White Reflective Devices
on Mudflaps or Hanger Brackets
2. Red and White Reflective Devices
(when not equipped with mudflaps
and brackets)
Note: The truck-tractor conspicuity standard is intended to make the tractor as visible
as the trailer when the truck tractor is being operated in a bobtail condition.
40 SAFETY INFORMATION
CAB ENTRY/EXIT
Three-Limb Contact
WARNING
When entering or exiting a cab, the driver and/or passenger must have at least
three limbs in contact with the vehicle or ground at all times. This means that a
minimum of two hands and one foot, or one hand and two feet must be in FIRM
contact with the vehicle or ground.
WARNING
When entering or exiting the cab, be aware of the condition of the steps and
handrails. Clean any fuel, oil or grease off of the steps before entering the cab.
During cold weather operation, ice and snow may accumulate and should be
cleaned off to prevent slipping.
During cold, wet conditions when ice, slush, or snow may accumulate on the
cab doorstep and other external surfaces, extra caution must be observed
when entering or exiting the cab.
SAFETY INFORMATION 41
WARNING
GUIDELINES FOR ENTERING AND EXITING TO AVOID SERIOUS
INJURY
• Face the cab when entering AND exiting.
• Place papers, coats, etc., in cab BEFORE entering. Take out AFTER exiting.
Keep hands free to grip handholds.
• Keep hands and shoes clean. Check hands and shoes for grease, mud, etc.,
BEFORE entering or exiting.
• Keep 3 limbs (2 hands and 1 foot or 1 hand and 2 feet) in FIRM contact with steps
and handholds at ALL times.
• Be sure of where you step and grab the handholds. Keep the areas clean.
• Be EXTRA careful in rainy, snowy, etc., weather.
• Do NOT jump from vehicle.
Note: The illustrations on the following pages are typical for purposes of emphasizing
a safe method for hand/foot placement and movement during cab entry/exit. Your
vehicle may not look exactly like the one pictured.
Note: The arrows in the illustrations are intended to show movement. Notice that
three-limb contact is maintained even when one foot, or one hand, is moving.
42 SAFETY INFORMATION
Driver Side
The following cab entry and exit procedures, along with the safety guidelines
outlined in Three-Limb Contact earlier in this section, should be used with
this MACK vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with your right
hand and the inside handhold with your left hand. Then raise one foot to the
bottom step. (See figure 1.)
2 Maintain a firm grip on the handholds and raise your other foot to the top step.
(See figure 2.)
3 While still gripping the handholds, raise one foot to the cab floor. (See figure 3.)
4 Move your right hand to the steering wheel. Bring the other foot inside the cab
and sit down. (See figure 4.)
Exit
To exit, follow the illustrations in reverse order:
1 With your right hand gripping the steering wheel and your left hand gripping the
inside handhold, stand up and face the inside of the cab. Move one foot to the
top step. (See figure 4.)
2 Move your right hand to the outside handhold. With one foot firmly on the top
step, lower the other foot to the bottom step. (See figure 3.)
3 Maintaining a firm grip on both handholds, lower the other foot to the ground.
(See figure 2.)
4 With both hands still firmly gripping the handholds, lower the other foot to the
ground. (See figure 1.)
SAFETY INFORMATION 43
C0029682
44 SAFETY INFORMATION
Passenger Side
The following cab entry and exit procedures, along with the safety guidelines
outlined in the Three-Limb Contact section, should be used with this MACK
vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with your left hand
and the inside handhold with your right hand. Then raise one foot to the bottom
step. (See figure 1.)
2 Maintain a firm grip on the handholds and raise your other foot to the top step.
(See figure 2.)
3 While still gripping the handholds, raise one foot to the cab floor. (See figure 3.)
4 Move your left hand to the cab interior. Bring the other foot inside the cab and sit
down. (See figure 4.)
Exit
To exit, follow the illustrations in reverse order:
1 With your left hand gripping the cab interior and your right hand gripping the
inside handhold, stand up and face the inside of the cab. Move one foot to the
top step. (See figure 4.)
2 Move your left hand to the outside handhold. With one foot firmly on the top step,
lower the other foot to the bottom step. (See figure 3.)
3 Maintaining a firm grip on both handholds, lower the other foot to the ground.
(See figure 2.)
4 With both hands still firmly gripping the handholds, lower the other foot to the
ground. (See figure 1.)
SAFETY INFORMATION 45
C0029683
46 SAFETY INFORMATION
Deck Plate Access
There may be a time when you will need to climb up behind the cab. If your
vehicle is equipped with a deck access package, steps and a handhold are
provided so you can get to this area safely. Review the rules in the Three-Limb
Contact section before climbing behind the cab.
Climbing Up
These procedures are illustrated on the following page:
1 Grab the handhold with both hands. Then move one foot to the bottom step. (See
figure 1.)
2 While still gripping the handhold, and with one foot planted firmly on the bottom
step, move your other foot to the middle step. (See figure 2.)
3 Then with one foot planted firmly on the middle step, move the other foot to the
top step. (See figure 3.)
4 Finally, move your other foot from the middle step onto the deck plate. (See
figure 4.)
Climbing Down
To climb down from behind the cab, follow the illustrations in reverse order:
1 Grab the handhold with both hands and move one foot to the top step. (See figure
4.)
2 While firmly gripping the handhold, and with one foot on the top step, move your
other foot to the middle step. (See figure 4.)
3 Then with one foot planted firmly on the middle step, place the other foot on the
bottom step. (See figure 3.)
4 With both hands still gripping the handhold, move your other foot from the middle
step to the ground. (See figure 2.)
5 Finally, move foot from bottom step to the ground. (See figure 1.)
SAFETY INFORMATION 47
C0029684
48 SAFETY INFORMATION
SAFETY TIPS FOR COLD WEATHER OPERATION
Driver Visibility
Poor driver visibility is not only annoying, but extremely unsafe under any
circumstance. Without proper maintenance of visibility-related components,
adverse weather conditions such as rain, snow and frost can seriously reduce
visibility. Take time before winter arrives to check the following:
•
Windshield Wipers
― Check windshield wiper operation and speeds.
― Inspect condition and travel of blades. Install new refills for any blades that are
cracked, brittle, torn, or coated with road oil along the wiping edge.
•
Windshield Washers
― Check operation of windshield washer.
― Inspect system hoses and replace if brittle or worn.
― Inspect washer reservoir. Drain and flush if dirt particles are evident in washer
solution.
― Fill reservoir with commercially available non-freezing type washer fluid.
CAUTION
Do NOT fill reservoir with water only. Even though non-freezing type washer fluid
is recommended, do not attempt to clear the windshield of ice by activating the
windshield washer and wipers. Ice accumulations should be removed manually
by using a scraper.
SAFETY INFORMATION 49
•
Heater/Defroster
― Check operation and blowers for speed control, noise and temperature.
― Inspect heater core for signs of corrosion and/or leakage.
― Check that the defroster blend door is operating correctly and that all ducting
is connected properly.
― Be sure that vents are not obstructed by debris or other objects.
Cab Door Seals and Key Locks
Hollow-core rubber weather seals around some cab doors may lose their
resilience in extremely cold temperatures (i.e., –40°C/–40°F and below).
Under these conditions, it may be necessary to drill holes to penetrate
the hollow core. This allows entrapped air to escape, thereby easing the
opening/closing of cab door(s).
Be sure to keep the key locks clean and dry to prevent occasional winter
freeze-up. Use of antifreeze lubricants is neither required nor recommended.
Outside Mirror Heater
In areas of frequent snowfall and ice, it may be beneficial to install heated
mirrors which will defrost and de-ice cab mirrors. Heated mirrors eliminate the
need to pull off the highway and stand on the roadside to scrape ice and snow
from the mirrors during winter driving conditions. Heated mirrors are available
either cab mounted or fender mounted.
C0029132
50 SAFETY INFORMATION
Air Horn Snow Shield
Installation of an air horn snow shield is recommended to prevent snow from
clogging the air horn bell (maintaining maximum sound output).
C0029133
Emergency Reflector Kit
All on-road vehicles are required to have an emergency reflector kit.
If the kit is installed from the factory, it includes red reflector triangles and can
be stored in one of the following locations:
•
•
•
Inboard side of rider seat
Left-hand luggage compartment of sleeper box
Between rider seat and rider side door
Fire Extinguisher (Optional)
Your vehicle may be equipped with a fire extinguisher which is located inside
your cab. Check your fire extinguisher regularly to make sure it is fully charged.
INSTRUMENTS AND CONTROLS 51
CAB INTERIOR
C0029685
1. Turn Signal, Hazard Switch and
HI/LO Beam
3. Cab Climate Control Panel
2. Instrument Panels
4. Foot Pedals
52 INSTRUMENTS AND CONTROLS
INSTRUMENT PANEL
Tell-Tales
A tell-tale is a display that indicates the actuation of a device, a correct or
defective condition, or a failure to function.
The operator should become familiar with these symbols in order to recognize
and react (if necessary) to the indicated condition. Tell-tale symbols are shown
in the instrument panel illustrations on the following pages.
Colors
To promote visual recognition internationally, specific colors for tell-tales
have been established. Unless governmental regulations (in the area where
the vehicle is to be used) or engineering directives specify otherwise, the
standard colors are:
• Blue – high-beam headlights/engine maintenance
• Flashing Green – turn signals
• Flashing Red – hazard condition involving the safety of personnel
• Steady Green – system in operation
• Steady Red – warning, immediate action required
• Amber – early warning, such as low fuel or Anti-Lock Brake System (ABS)
malfunction
Panel Arrangement
Your view from the driver seat should look something like the illustrations
shown. The layout is designed to provide the operator with a good view of the
gauges and controls (which are placed so they are within easy reach). The
instrument panel, as shown in the following drawing, is broken down into
several main sections. For easy identification we refer to them, from left to
right, as Panels A, B, C, D, E and F (where necessary).
Note: This section shows the instruments and controls available for this vehicle at the
time of publication. However, depending on options, your vehicle may not have all
the instruments and controls shown here, and they may not be in the same position.
INSTRUMENTS AND CONTROLS 53
INSTRUMENT PANEL GAUGE LAYOUT
C0029686
Panel A
C0029687
1. Light Control Panel
54 INSTRUMENTS AND CONTROLS
Panel B
W3056180
2. Coolant Temperature Gauge
8. Turn Signal Indicator
3. Tachometer
9. Transmission Oil Temperature
Gauge
4. Oil Pressure Gauge
10. Voltmeter
5. Warning/Indicator Lamp Panel
11. Mode Button
6. Speedometer/Odometer
12. Hour Meter
7. High Beam Indicator
INSTRUMENTS AND CONTROLS 55
Panel C
W3055681
13. Optional Switch
18. Cab Climate Control Panel
14. Hand Control Brake Lever (If
Equipped)
19. Fuel / DEF Gauge
15. Optional Switch
20. Air Pressure Gauge
16. Optional Switch
21. Park Brake Valve
17. Air Vent
22. Ignition Switch
56 INSTRUMENTS AND CONTROLS
Panel D
C0029690
23. Windshield Wiper/Washer Control
Switch
27. Optional Switch
24. DPF Smart Switch (If Equipped)
28. Optional Switch
25. Speed Control Switch
29. Optional Switch
26. Resume/Set Switch
30. Optional Switch
INSTRUMENTS AND CONTROLS 57
Panel E
C0029691
31. Air Filter Restriction Indicator (If
Equipped)
33. Accessory Power Outlet or Cigar
Lighter
32. Exhaust Pyrometer (If Equipped)
34. Push Button Start (If Equipped)
1. Light Control Panel — See the LIGHT CONTROL PANEL section for
more information.
2. Coolant Temperature Gauge — Indicates the temperature of the engine
coolant. The normal operating temperature for MACK MP engines is between
77°C and 107°C (170°F and 225°F). The driver will receive a warning if
coolant temperature reaches 223°F and engine shutdown will occur at 227°F
if the engine coolant temperature shut down option is enabled.
CAUTION
Coolant temperature must NOT exceed 107°C (225°F).
3. Tachometer — Indicates engine speed in revolutions per minute (RPM).
Tachometer readings should be used as a guide for shifting, as well as to
prevent engine damage due to overspeed. The blue band indicates the
optimum range for engine brake operation.
4. Oil Pressure Gauge — Indicates engine oil pressure. The normal
operating oil pressure for a MACK MP engine (at governed speed) is between
275.8 and 620.5 kPa (40 and 90 psi). At idling speed, the oil pressure should
be between 275.8 and 413.9 kPa (40 and 60 psi).
58 INSTRUMENTS AND CONTROLS
Should the oil pressure drop suddenly from normal readings, stop the engine
immediately and determine the cause.
5. Warning/Indicator Lamp Panel — Items listed below from left to right
and top to bottom.
W3056178
Detail of Warning/Indicator Light Panel
• Optional Tell-Tales
• Malfunction Indicator lamp (MIL)— MIL indicates government Regulation
On Board Diagnostics (OBD) faults. Lamp remains active after repair until
system operation confirms repair.
• Electronic Malfunction Indicator (Amber) — Illuminates when V-MAC®
detects an electronic malfunction. Refer to the appropriate V-MAC®
Operator’s Guide for details.
• Engine Shutdown Indicator (Red) — Indicates the occurrence of a
condition which requires that the engine be shut down (i.e., low water level,
low oil pressure or high water temperature). If the engine shutdown feature
is enabled, the operator has about 15 seconds after the light goes on to pull
to the side of the road before the engine shuts off. If the engine shutdown
feature is disabled, the indicator will function as a warning light but the engine
will not shut down.
• Optional Tell-Tales
• Aftertreatment DEF tank Low Level Indicator (DEF)— Illuminates when
the fluid level is low. It also Flashes when the level becomes critically low.
• Reverse Indicator — Indicates that the transmission is in Reverse.
• Optional Tell-Tales
INSTRUMENTS AND CONTROLS 59
• Low Air Pressure Warning Indicator — Indicates low air pressure in the air
brake system(s). This feature may also come with a buzzer.
• Parking Brake Indicator — Indicates that the parking brake is engaged.
• Optional Tell-Tales
• HEST Indicator (Amber) — The High Exhaust Temperature (HEST) indicator
is displayed when the exhaust temperature reaches 300°C (572°F) and the
regeneration process begins. When the regeneration process is completed,
the engine should be allowed to run until the HEST indicator shuts off.
During regeneration while the vehicle is moving, the HEST indicator will only
illuminate when vehicle speed is less than 8 kph (5 mph).
During a parked regeneration, the HEST indicator will turn off when
regeneration is complete and the exhaust temperature has returned to a
normal temperature.
C0029146
HEST Indicator
• Neutral Indicator — Indicates that the transmission is in Neutral.
• Optional Tell-Tales
• Anti-Lock Brake System (ABS) Indicator (Amber) — Indicates an ABS
malfunction. Also illuminates momentarily as a bulb check when the ignition
is turned on. If the light turns on and stays on, a malfunction is indicated. If
the light does not turn on when the ignition is turned on, the bulb and the
power source may be defective. For additional information on operating an
ABS-equipped vehicle, refer to “Anti-Lock Brake System (ABS)”, page 130,
in the OPERATION section.
Note: When an ABS malfunction is detected, anti-lock braking in the affected wheel
will be disabled and normal braking will return; the other wheels will retain anti-lock
braking.
• Automatic Traction Control (ATC) Indicator — Indicates that ATC is
operating.
• Optional Tell-Tales
• Aftertreatment DPF Regeneration Required Icon — Flashes when the
Diesel Particulate Filter is becoming full/overful and regeneration is needed.
60 INSTRUMENTS AND CONTROLS
• Check Transmission Warning Indicator (If Equipped) — Only present on
vehicles equipped with automatic transmission.
• Optional Tell-Tales
• Right-Hand Operation Indicator — Indicates that a right-hand drive mode
has been enabled.
• Maintenance Due Indicator — Indicates that a maintenance alert has been
issued (maintenance is due).
• Optional Tell-Tales
• Aftertreatment DPF Regeneration Inhibit Icon — Illuminates when the
inhibit switch is turned on. It will allow the driver to know that the switch is in a
inhibit position and a regeneration will not occur.
• Forced Neutral Indicator — Illuminates when PTO is engaged and the
truck is not moving.
• Fuel Filter Restriction (If Equipped)
• Air Filter Restriction (If Equipped)
• Predictive Oil Change (If Equipped)
• Engine Oil Level Indicator — If illuminated, immediately check the level of
your engine oil.
• Water in Fuel Indicator (If Equipped) — Illuminates when water
accumulates in the primary fuel filter sediment bowl. Stop the engine and
drain the fuel from the sediment bowl.
6. Speedometer/Odometer — Indicates road speed in miles and/or
kilometers per hour and total distance vehicle has traveled.
7. High Beam Indicator (Blue) — Indicates that high beams are on.
8. Turn Signal Indicators — Flash green when the turn signals are activated.
9. Transmission Oil Temperature Gauge (If Equipped) — Indicates
transmission oil temperature.
10. Voltmeter — Indicates the surface charge of the battery with the engine
NOT running (and the ignition ON). Indicates the condition of charging system
with the engine running.
The voltmeter can be useful as a diagnostic tool. During cranking, the reading
should not drop below 10 volts. Lower readings may indicate corroded
connections at the cranking motor or battery terminals, or discharged or
defective batteries.
INSTRUMENTS AND CONTROLS 61
11. Mode Button — Using this button will display diagnostic trouble code
information and trip distance in the odometer. When you press and hold down
this button, the display will go through a gauge self test. After the self test is
complete, diagnostic trouble code information will be displayed, by MID, in the
speedometer/odometer screen. When the first MID is displayed, push the
Mode button again to display the 1st diagnostic trouble code for this MID.
At the end of the diagnostic trouble code list for each MID, "CLEAR" will be
displayed. You have the option here to clear the codes for this MID. If you
choose to do so, press and hold the Mode button. Once the codes are cleared
for this MID, the next MID will be displayed.
By pressing this button once (NOT holding it down), information for Trip 1
distance will be displayed. Press and hold the Mode button to clear Trip 1
information.
By pressing this button twice, information for Trip 2 distance will be displayed.
Press and hold the Mode button to clear Trip 2 information.
12. Hour Meter — Indicates hours of engine operation. Hours of operation
should be used as a guide for certain engine or PTO maintenance operations.
13. Optional Switch — See “Function of Optional Switches”, page 71.
14. Hand-Control Brake Lever (If Equipped) — Pull down to activate the
trailer brakes, or the rear axle brakes in the case of a platform truck.
Note: There are only two instances when the feature should be used: (1) momentary
brake application at a stop sign, light, etc., or (2) to apply the trailer brakes while
sliding a 5th wheel.
WARNING
The hand-control brake system must NOT be used for parking. Do NOT use
to apply service brakes while vehicle is in motion. Do not leave the vehicle
while hand-control brake is applied.
15. Optional Switch — See “Function of Optional Switches”, page 71.
16. Optional Switch — See “Function of Optional Switches”, page 71.
17. Air Vent — Rotate the knob to open or close the air vent.
18. Cab Climate Control Panel — See the CAB CLIMATE CONTROL
section for more information.
19. Fuel/ DEF Gauge— Registers the fuel and DEF levels in the supply
tank(s).
62 INSTRUMENTS AND CONTROLS
CAUTION
The maximum safe oil temperature for MACK transmissions is 121°C (250°F) for
mineral-based oil, or 148°C (300°F) for synthetic oil. Continued operation with
oil above this temperature will cause rapid deterioration of the oil’s lubricating
properties and is NOT recommended. Consult the vendor manual for non-MACK
components.
20. Air Pressure Gauge — Indicates the air pressure in the air brake
system(s). The normal operating air pressure is between 759 kPa (110 psi)
and 897 kPa (130 psi) in both air brake systems. If pressure drops below 75
psi (±5 psi) in either system, the warning buzzer and warning light will go
on. Determine the cause of failure before proceeding. Primary air pressure
is supplied to the rear brakes and is indicated by the green pointer on the
gauge. Secondary air pressure is supplied to the steering axle brakes and
indicated by the orange pointer.
21. Park Brake Valve — Yellow diamond-shaped knob. Pull to apply. Push to
release. Applies the parking brakes.
Note: The parking brake DRL allows the daytime running lights to be off while the
concrete pumper is in operation.
22. Ignition Switch — Refer to STARTING THE VEHICLE in the OPERATION
section for specific starting procedures. Insert the key into the switch. Turn
the key clockwise to the ON position. To crank the engine, turn the key
clockwise or push the optional starter button. To shut down the engine, turn
the key to the left.
23. Windshield Wiper/Washer Controls — Depress the ON/OFF button to
turn the windshield wipers on or off. Pull the button up to make the wipers
faster, push the button down to make the wipers slower. Depress the "WASH"
button to activate the washer fluid.
C0029692
INSTRUMENTS AND CONTROLS 63
24. DPF Smart Switch (If Equipped) — This is a three-position switch where
the middle position is neutral.
C0029592
1. Upper Position — Regeneration
Position
3. Down Position — Inhibit Position
2. Middle Position — Neutral Position
Regeneration
"Moving" regeneration occurs while the vehicle is being driven and is
automatic (no operator input needed to start regeneration) or manual
(operator input needed to start regeneration). The operator is notified that a
regeneration is needed when the icons on the DPF Smart switch illuminate
(refer to Figure listed below).
Note: During vehicle operation, idle speed may increase when the vehicle is stopped
at a traffic light to maintain proper Aftertreatment DPF Regeneration conditions.
(Manual Moving ) Regeneration (If Available)
1 When the icons on the DPF Smart switch light up, maintain vehicle speed and
press and hold the top part of the switch momentarily.
2 During regeneration, the icons on the switch will shut off.
3 Regeneration will take between 45 to 60 minutes to complete.
4 To stop regeneration, press the switch down to the inhibit position. When the
bottom of the switch is illuminated, regeneration is stopped. The switch will
remain locked in this position and the light will stay illuminated. The driver has
the option of stopping a regeneration if the vehicle is in an area where elevated
exhaust temperatures will pose a hazard (i.e., tunnel, under trees, in an area where
there is flammable material, etc.).
64 INSTRUMENTS AND CONTROLS
Depending on the vehicle’s set up, it may be possible to perform a parked
regeneration if necessary.
INSTRUMENTS AND CONTROLS 65
Parked Regeneration (If Needed)
Parked regeneration allows the operator to start and/or stop the regeneration
manually when the vehicle is parked and the engine is idling. The operator is
notified that a regeneration is needed when the icons on the DPF Smart switch
illuminate. The operator should perform the regeneration as soon as possible.
Please refer to the instructions below on how to use the DPF Smart switch for
parked regenerations.
1. Move the vehicle to a safe location, apply the park brake and allow the
engine to idle.
WARNING
When a regeneration is in process, the temperature of the exhaust will be
elevated. DO NOT park the vehicle with the exhaust outlet under low hanging
overhead flammable objects such as trees, awnings, etc., that could be damaged
by elevated exhaust temperatures. DO NOT attempt to regenerate inside a
garage or enclosed area if the tail pipe is attached to an exhaust ventilation
system as the hose material may not be rated for the high temperature.
2. Press and hold the top part of the DPF Smart switch momentarily to initiate
the regeneration.
3. During regeneration, the icons on the switch will shut off. The HEST
indicator on the instrument cluster will light up to notify of high exhaust
temperatures.
4. Engine speed will ramp as high as 1,300 rpm.
5. Regeneration will take between 45 to 60 minutes to complete.
6. After regeneration has completed and the exhaust temperature has
returned to normal, the HEST indicator will shut off.
7. To stop regeneration, press the switch down to the inhibit position. When
the bottom of the switch is illuminated, regeneration is stopped. The switch
will remain locked in this position and the light will stay illuminated. The driver
has the option of stopping a regeneration if the vehicle is in an area where
elevated exhaust temperatures will pose a hazard (i.e., tunnel, under trees, in
an area where there is flammable material, etc.).
66 INSTRUMENTS AND CONTROLS
CAUTION
Failure to perform a regeneration in a timely manner after notification may result
in engine derate, a clogged diesel particulate filter, damage to the filter and engine
shutdown.
DANGER
During the regeneration process (with either system), the temperature of
the exhaust gases will be elevated. DO NOT park or stop for an extended
period under low hanging overhead flammable objects such as trees, awnings,
structures, etc., that could be damaged by elevated exhaust temperatures.
Further, if the vehicle is being operated in an area where flammable vapors exist,
the regeneration process must be interrupted. Failure to heed these cautions may
result in fire or explosion causing serious personal injury or death.
When regeneration is needed, an icon at the top of the DPF Smart switch will
illuminate to notify the vehicle operator. The DPF Smart switch allows the
vehicle operator to either stop or start regeneration. (Certain conditions must
be met, however, before regeneration can be manually started.)
Note: If the vehicle is in a location that may be hazardous when an active regeneration
begins (i.e., in close proximity to flammable materials or gases), the regeneration
should be stopped by pushing the DPF switch to the "Stop Regeneration" position.
If an active regeneration is stopped by the vehicle operator, it should be initiated at a
later time when the vehicle is in a safe location. However, if an active regeneration is
stopped the vehicle may need to be taken to a MACK service facility. The service
facility will use a service tool to manually initiate the regeneration.
WARNING
The temperature of the exhaust system components during the regeneration
process can exceed 500°C (1000°F). Various factors (including ambient
temperature and duration of the regeneration process) determine when these
components will return to normal operating temperature after regeneration
has completed. Be extremely careful around these hot components. Contact
with these components can result in serious personal injury.
INSTRUMENTS AND CONTROLS 67
CAUTION
When the inhibit position is pressed, the switch will remain in a locked position. It
is important, therefore, to immediately set the switch back to the neutral position
when safe to do so. Failure to set the switch back to the neutral position may result
in an engine derate, clogged diesel particulate filter or damage to the filter.
DPF INHIBIT ROAD SPEED LIMITING (RSL)
The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen)
position by the driver. If the DPF Smart Switch remains in the locked position,
the following vehicle speed limiting will occur:
1 Vehicle Moving. If vehicle is moving with the DPF Smart Switch in the locked
(DOWN) position, the vehicle speed will decrease down to 16 kph (10 mph) below
the current speed until the driver releases the switch back to the neutral (MIDDLE)
position.
2 Vehicle Stationary and then Moving. If the vehicle is stationary with the DPF
Smart Switch in the locked (DOWN) position and the driver then begins to move
the truck, the vehicle speed will be limited to 16 kph (10 mph) until the driver
releases the switch back to the neutral (MIDDLE) position.
68 INSTRUMENTS AND CONTROLS
The following label is located on the driver-side sun visor which provides
additional instructions on the exhaust aftertreatment system.
W8029446
For more information on the DPF Smart Switch, please refer to the V-MAC®
IV Operator’s Guide
INSTRUMENTS AND CONTROLS 69
25. Speed Control Switch — This is a V-MAC® switch; refer to the applicable
V-MAC® Operator’s Guide for more information.
C0029150
26. Resume/Set Switch — This is a V-MAC® switch; refer to the applicable
V-MAC® Operator’s Guide for more information.
C0029211
27. Optional Switch — See “Function of Optional Switches”, page 71.
28. Optional Switch — See “Function of Optional Switches”, page 71.
29. Optional Switch — See “Function of Optional Switches”, page 71.
30. Optional Switch — See “Function of Optional Switches”, page 71.
31. Air Filter Restriction Indicator (If Equipped) — Indicates that the
element needs servicing or replacement. When the red flag locks into position,
service as soon as possible to prevent engine damage; then reset the indicator
after the filter change. Check the air filter restriction indicator daily.
32. Exhaust Pyrometer (If Equipped) — Indicates the temperature of
exhaust gas at inlet of diesel particulate filter assembly. This helps the
operator select the proper gear for load and grade conditions, thereby avoiding
excessive exhaust temperatures. The maximum operation temperature is
shown on the nameplate of the pyrometer glass.
70 INSTRUMENTS AND CONTROLS
CAUTION
Do NOT exceed the maximum exhaust temperature indicated by the red line on
the gauge. To reduce exhaust temperature, downshift or reduce engine power. If
operating in cold climates with a winterfront, open the winterfront.
33. Accessory Power Outlet — See instructions under Accessory Power
Outlets listed in the Instrument and Controls Section of this manual.
OR
Cigar Lighter — Press in the lighter; it will pop out when element is hot.
CAUTION
Maximum amperage for the in-dash cigar lighter is 10 amps. Do NOT use the cigar
lighter receptacle to power accessories rated higher than 10 amps.
34. Push-Button Start Switch (If Equipped) — After turning the ignition ON,
depress this button until the engine fires. See "STARTING THE VEHICLE" in
the OPERATION section of this manual for specific starting instructions.
INSTRUMENTS AND CONTROLS 71
Function of Optional Switches
C0029693
1. Air Suspension Control Switch
6. Mirror Control Switch
2. Automatic Traction Control Switch
7. Mirror Defrost Switch
3. Engine Brake Switch
8. Neutral Control Switch
4. Shutdown Override Switch
9. Power Divider Lockout Switch
5. Fuel Primer Pump Switch
10. Power Take-Off Control Switch
The following optional switches, listed in alphabetical order, may appear on
Panel D, shown on “Panel D”, page 56.
• Air Suspension Control Switch — This switch exhausts the air from the air
bags of the suspension. It may be used when coupling or uncoupling trailers.
72 INSTRUMENTS AND CONTROLS
CAUTION
When preparing to connect a tractor to a trailer, make sure that the height of the
5th wheel matches the height of the underside of the trailer. Failure to do so will
result in the trailer being improperly connected. After the trailer has been coupled
and the trailer landing gear has been raised, make sure that the 5th wheel jaws
have properly engaged the trailer king pin, and there is no gap between the 5th
wheel plate and the bottom of the trailer.
CAUTION
DUMP BODY: Always exhaust the air from the bags before raising the dump
body to protect the air bags and improve chassis stability while dumping. If the
dump body is raised while the air suspension is pressurized, damage to the air
bags may result.
CAUTION
Do not drive the vehicle with the air bags exhausted. Repressurize the air bags
before driving the vehicle.
• Automatic Traction Control Switch/Heavy Mud/Snow – Activate for
increased traction control in heavy mud or snow. (See “Automatic Traction
Control (ATC) (If Equipped)”, page 134 in the OPERATION section of this
manual for more details.) When the operator presses the top of the rocker
switch, the heavy mud/snow function ATC indicator lamp blinks continuously.
The ATC lamp stops blinking when the ATC mode switch is pressed again
or ignition key cycled.
CAUTION
Be sure to deactivate the heavy mud/snow function when no longer needed.
Continued operation with the heavy mud/snow function active will result in vehicle
damage. If after a reasonable amount of time (no more than five minutes) the
vehicle is still not moving, deactivate the ATC and put on chains.
INSTRUMENTS AND CONTROLS 73
• Engine Brake Switch – Used to activate the engine brake. Refer to the
OPERATION section in this handbook for more information.
• Heated Mirrors Switch – Activates the outside heated mirrors (for use in icy
conditions).
• Mirror Control Switch – Push the top in to turn the mirror to the left. Push
the bottom in to turn the mirror to the right.
• Neutral Control Switch – Shifts the rear compound to neutral on certain
transmissions for rear case power take-off operation.
• Power Divider Lockout Switch – See "Inter-Axle Power Divider Lockout (If
Equipped)" in the OPERATION section of this manual.
• Power Take-Off Control Switch — Push the top in to turn the PTO on.
Push the bottom in to turn it off.
• Shutdown Override Switch — Pressing this switch shortly after the vehicle
sounds the engine shutdown alarm, allows 30 additional seconds of operation.
This process can be repeated several times to safely park the vehicle.
• Telma Rear Axle Mounted Retarder Indicator Lamp (If Equipped) — The
Telma does not have a disable switch. It is always on and will operate different
levels depending on application of service brake. The indicator will show you
the level you are retarding the vehicle: 20%, 40%, 60%, 80% or 100%.
Note: The Telma retarder is disabled if there is an ABS event.
C0029217
Telma Retarder
74 INSTRUMENTS AND CONTROLS
CAB CLIMATE CONTROL
C0029694
1. Blower Control Knob
4. Fresh/Recirculation Button
2. Mode Knob
5. A/C ON/OFF Button
3. Temperature Control Knob
1. Blower Control Knob — Controls the amount of air delivered through the
vents. Move lever for desired fan speed from OFF (far left) to HIGH (far right).
2. Mode Selection Knob — Allows the operator to choose the air direction.
The FOOT position delivers air to the floor outlets, while the DEF position
directs air to the windshield for defogging and/or defrosting. The FACE
position delivers air to the vents on the dash panel for the upper body.
3. Temperature Control Knob — Controls the temperature of air from COOL
(far left) to HOT (far right).
4. Fresh/Recirculation Button — This button lets the operator choose
between fresh air (from the outside) and recirculated air (within the cab).
5. Air Conditioner On/Off Button — Activates the air conditioning system.
CAUTION
If your vehicle is equipped with air conditioning, the air conditioner unit should be
run for FIVE MINUTES at least ONCE A WEEK throughout the year to keep the
moving parts well lubricated.
INSTRUMENTS AND CONTROLS 75
LIGHT CONTROL PANEL
The light control panel is located on the driver side of the dash. This panel
controls the parking lights, interior panel lights, headlights and fog lights (if
equipped).
C0029600
1. Light Control Knob/Pull for Fog
3. Dome Lamps
2. Panel Dimmer Switch
With the light control knob in the left position, all lights are off. With the knob in
the middle position, the parking lights and interior panel lights will illuminate.
With the knob in the far right position, the headlights will turn on.
To turn on the fog lights (if equipped), put the knob in the far right position
and pull out the fog light button (see Figure above). The fog light symbol will
illuminate indicating the lights are on.
To adjust the intensity of the panel light, roll the panel dimmer switch up and
down.
To turn on the dome lamps, push the right switch up. To turn the dome lamps
off, push the switch down.
76 INSTRUMENTS AND CONTROLS
STEERING COLUMN
Electrical Switch
Turn Signal Lever
Note: The turn signals are not self-cancelling and must be returned to the middle
position manually.
The turn signal lever is located on the steering column. It performs a number
of functions, including activating the high and low beams and the hazard
switch (see illustration below).
C0029601
1. Handle in Right Turn Position and
Cancel Position of Hazard Warning
3. Pull for Warning Hazard Position
2. Handle in Left Turn Position and
Cancel Position of Hazard Warning
4. Push Button for Hi/Lo Beam
INSTRUMENTS AND CONTROLS 77
FLOOR PEDALS
C0029695
1. Accelerator Pedal — Depress to increase engine/vehicle speed; release
to decrease engine/vehicle speed.
2. Brake Treadle Valve — Depress to activate the service brakes.
3. Clutch Pedal — Depress to disengage the clutch. The clutch pedal is only
found on trucks equipped with manual transmissions.
78 INSTRUMENTS AND CONTROLS
MISCELLANEOUS CONTROLS
Dome Light
C0029228
Dome Light
C0029229
Driver Side Switch
C0029230
Passenger Side Switch
With the switch in the bottom position on the driver side and on the passenger
side, the dome light will come on when the cab door is opened and go off
when it is closed. Push the switch up to turn the dome light on when the doors
are closed for either the driver side or the passenger side. Depress the CAB
switch above the driver up when doors are closed to turn both dome lights on.
INSTRUMENTS AND CONTROLS 79
Air Horn
C0029603
The air horn(s), if equipped, is activated by pulling down on the cord that is
located above the driver near the overhead console.
Fresh Air Vent
C0029696
An air vent is provided to circulate outside air to the cab interior. Move the vent
wheel up to open the vent. Move the wheel to the bottom to close the vent.
Accessory Power Outlets
Additional 12-volt accessory power outlets are located next to the driver on the
"E" panel. These cigar light-type outlets supply 12 volts of fused (20A) power
when the ignition switch is turned to the ignition or accessory position.
80 INSTRUMENTS AND CONTROLS
C0029697
CAUTION
Maximum amperage for all power receptacles in cab is 10 amps. Do NOT exceed
maximum amperage as equipment damage may result.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 81
PRE-TRIP
DANGER
Before working on or inspecting a vehicle, set the parking brakes, place the
transmission in neutral and block the wheels. Failure to do so can result in
unexpected vehicle movement and can cause serious personal injury or death.
Safety is the most important and obvious reason for doing a pre-trip inspection.
Federal and state laws require inspection performed by the driver. Federal
and state inspectors also inspect commercial vehicles. An unsafe vehicle can
be placed "out of service" until the driver or owner corrects the deficiency.
Owners and operators should familiarize themselves with sections 49 CFR
396.11 and 396.13 concerning Federal requirements for vehicle inspection.
Certain other laws may also apply.
Section 49 CFR 396.13 states that all motor carrier drivers must complete a
written report at the end of each work day for each vehicle operated, covering
most of what is covered in the pre-trip list. The report should list all defects
or deficiencies discovered by the driver. A pre-trip inspection prepares for
the end-of-work report.
Starting on the next page are suggested guidelines to be used in performing
truck, tractor and trailer pre-trip inspections. Depending on the application of
the vehicle being used, these guidelines should be modified to include other
necessary inspection points. For example, steps and grab handles should be
checked daily on refuse trucks because the operator is getting in and out
of the cab more frequently.
If any component or system does not pass this inspection, it must be corrected
before operating the vehicle. Whenever equipment requires adjustment,
replacement, repair or lubrication, refer to the Service Manuals or contact
an authorized Mack Truck dealer for the correct procedures, specifications
and intervals.
Take your time going through the pre-trip inspection. Remember that a careful
pre-trip inspection saves time by eliminating unscheduled stops for correcting
a faulty item.
The following information has been provided by the American Trucking
Association as developed by the D.O.T. Office of Motor Carriers (BMCS).
Pre-Trip Inspection Quick List
Inspect the vehicle in a circular manner.
Approaching the Vehicle
82 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
• Check under the vehicle for oil, fuel, coolant leaks or other signs of damage.
• Check body surfaces for signs of breaks or damage.
Preparation
• Open drain cocks on air tanks to let the tanks drain.
• Chock wheels on vehicle and, if hooked up, trailer.
• Close air tank drain cocks.
• Start the engine and let the air pressure build up to normal. Stop engine.
• Switch on parking lights and hazard lights.
• Apply parking brakes.
• Pull the hood release lever or release the hood latches, raise hood.
Step 1: Left Side of the Cab
Left Front Wheel
• Check condition of wheel rim. Especially look for cracks, missing lockrings,
bent or broken studs, clamps or lugs.
• Check condition of tire: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stem not touching wheel, rim or
brake drum; valve cap in place.
• Check wheel bearing and hub: no obvious leaking on outside or inside
wheel. Verify correct oil level in hub.
Left Front Suspension
• Check condition of spring, spring hangers, shackles, U-bolts: no cracks,
breaks or shifting.
• Check shock absorber condition.
Left Front Brake
• Condition of brake drum. With brakes released, look for a noticeable gap
between lining and drum. (This check cannot be made if dust covers are
in place.)
• Condition of brake air hose.
• Check brake chamber mounting bolts and bracket.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 83
Condition of Front Axle and Steering System, Left Side
• No loose, worn, bent, damaged or missing parts.
Under Hood, Left Side
• Check coolant hose condition.
• Check condition of fan drive belts.
• Check engine and surrounding areas for coolant, oil and fuel leaks.
• Check wiring harnesses for signs of damage.
Step 2: Front of Cab Area
Condition of Windshield
• Check for damage and clean if dirty.
• Check windshield wiper arms for proper spring tension.
• Check wiper blades for any damage, "dead" rubber and attachment to arm.
Lights and Reflectors
• Lower hood and inspect parking, clearance and identification lights on hood
and cab. They should be clean and of the proper color.
• Reflectors clean and proper color.
• Left and right front turn signal lights and headlights clean and proper color.
Raise hood.
Grille
• Check that charge air cooler and radiator or bugscreens are clean and
undamaged.
Step 3: Right Side of Cab Area
Right Front Wheel
• Check condition of wheel rim. Especially look for cracks, missing lockrings,
bent or broken studs, clamps or lugs.
• Check condition of tire: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stem not touching wheel, rim or
brake drum; valve cap in place.
84 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
• Check wheel bearing and hub: no obvious leaking on outside or inside
wheel. Verify correct oil level in hub.
Right Front Suspension
• Check condition of spring, spring hangers, shackles, U-bolts: no cracks,
breaks or shifting.
• Shock absorber condition.
Right Front Brake
• Condition of brake drum. With brakes released, look for a noticeable gap
between lining and drum. (This check cannot be made if dust covers are
in place.)
• Condition of brake air hose: check for any chafing.
• Check brake chamber mounting bolts and bracket.
• With brakes applied or released, look for conspicuously different positions
of the slack adjusters.
Condition of Front Axle and Steering System, Right Side
• No loose, worn, bent, damaged or missing parts.
Under Hood, Right Side
• Check condition of coolant and heater hoses.
• Check condition of fan drive belts.
• Check engine and surrounding areas for coolant, oil and fuel leaks.
• Check fuel separator sight glass and drain if necessary. Check for leaks.
• Check wiring harnesses for signs of damage.
• Check air filter with brackets and hoses for loose connections or damage.
Check filter gauge, if mounted on the filter.
Step 4: Right Saddle Tank Area
Right Fuel Tank(s)
• Securely mounted and not damaged or leaking.
• Fuel lines secure and not leaking. Check that shut-off valves are open.
• Tank(s) full of fuel. Cap on and secure.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 85
Condition of Visible Components
• Rear of engine: not leaking.
• Transmission: not leaking. If equipped with oil cooler, check cooler, hoses
and fittings for leaks.
• Check drive shaft.
• Exhaust system: secure, not leaking, not touching wires, fuel or air tubing.
• Frame and cross members: no bends, cracks or breaks.
• Air tubing and electrical wiring: secured against snagging and chafing.
Step 5: Right Rear Vehicle Area
Dual Wheels, One or Two Axles
• Check condition of wheels and rims. Especially look for cracks, missing
lockrings, bent or broken spacers, studs, clamps or lugs.
• Check condition of tires: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stems not touching wheels, rims or
brake drums; valve caps in place and no objects stuck between the wheels.
• Check that both tires are of same type, for example, not mixed radial and
bias type and that their circumferences are matched.
• Check wheel bearing and hub: no obvious leaking on outside or inside wheel.
Suspension
• Check condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
Brakes
• Condition of brake drums. With brakes released, look for a noticeable gap
between lining and drum. (This check cannot be made if dust covers are
in place.)
• Condition of brake hoses: check for any chafing.
• Check brake chamber mounting bolts and brackets.
• With brakes applied or released, look for conspicuously different positions
of the slack adjusters.
86 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
Step 6: Rear of Vehicle Area
Frame Area
• Frame or cross members not bent, cracked or otherwise damaged or missing.
• Check that air tubing and electrical lines are properly secured to the frame
with no damage or chafing.
Lights and Reflectors
• Tail lights, brake lights and turn signal lights: clean and proper color.
Step 7: Coupling System Area
Fifth Wheel
• Securely mounted to the frame.
• No missing or damaged parts.
• Check that trunnion and plate are properly lubricated.
Sliding Fifth Wheel
• Mechanism not worn, bent, damaged or parts missing.
• Properly lubricated.
• All locking pins present and locked in place.
• If air operated: no air leaks.
Air Tubing and Electric Lines Visible From This Point
• Should be secure from dangling.
• Both air lines and electric line should be free from damage, oil and grease.
Step 8: Left Saddle Tank and Left Rear Vehicle Wheels Area
Dual Wheels, One or Two Axles
• Check condition of wheels and rims. Especially look for cracks, missing
lockrings, bent or broken spacers, studs, clamps or lugs.
• Check condition of tires: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stems not touching wheels, rims or
brake drums; valve caps in place and no objects stuck between the wheels.
• Check that both tires are of same type, for example, not mixed radial and
bias type and that their circumferences are matched.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 87
• Check wheel bearing and hub: no obvious leaking on outside or inside wheel.
Suspension
• Check condition of springs (leaf or air), spring hangers, shackles and U-bolts,
no cracks, breaks or shifting.
Brakes
• Condition of brake drums. With brakes released, look for a noticeable gap
between lining and drum. (This check cannot be made if dust covers are
in place.)
• Condition of brake hoses: check for any chafing.
• Check brake chamber mounting bolts and brackets.
• With brakes applied or released, look for conspicuously different positions
of the slack adjusters.
Condition of Visible Components
• Transmission: not leaking.
• Drive shaft: looks OK.
• Exhaust system: secure, not leaking, not touching wires, fuel or air tubing.
• Frame and cross members: no bends, cracks or breaks.
• Air tubing and electrical wiring: secured against snagging and chafing.
Left Fuel Tank(s)
• Securely mounted and not damaged or leaking.
• Fuel lines secure and not leaking. Check that shut-off valves are open.
• Tank(s) full of fuel. Cap on and secure.
Battery Area
• Open the battery box. Battery box securely mounted to vehicle.
• Batteries secured against movement.
• Battery cases not broken or leaking. Battery cables free from damage.
• Tops of batteries and terminals clean and free from foreign material.
• If equipped, replace battery lid and make sure it is securely fastened.
88 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
Step 9: Trailer Front Area
Air and Electrical Connections
• Glad hands properly mounted, free from damage and not leaking.
• Trailer cord receptacle properly mounted, free of damage; plug properly
seated and safety catch engaged to prevent accidental disconnect.
• Air and electrical lines properly secured against tangling, snagging and
chafing with sufficient slack for turns.
Hooking Up To Trailer
Hook-Up Preparation
• Check kingpin and mounting plate on trailer, free from wear, bends or
damage.
• Chock trailer wheels.
Fifth Wheel or Trailer Hitch
• No visible space between fifth wheel and trailer.
• Locking jaws around the shank and not the head of kingpin.
• Release lever properly seated and safety latch/lock engaged.
• Check all connections to dolly or trailer hitch and safety chains are secured.
• Check function of trailer air supply valve and trailer brakes.
Sliding Fifth Wheel
• Check that fifth wheel is not so far forward that the tractor frame will strike
the landing gear during turns.
Note: Refer to the trailer manufacturer’s manual for specific information on the
trailer checks.
Step 10: Right Side of Trailer Area
Landing Gear or Dolly Area
• Fully raised; no missing or damaged parts.
• Crank handle present and secured.
• If power operated, no air/hydraulic leaks.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 89
Spare Wheel(s)
• Carrier or rack not damaged.
• Spare wheel securely mounted in rack.
• Tire and wheel condition adequate for a spare: proper size, properly inflated.
Lights and Reflectors
• Trailer side clearance lights: clean, operating and proper color.
• Reflectors clean and proper color.
Frame and Body
• Frame and crossmembers not bent, cracked, damaged or missing.
• Proper placarding.
• Body parts not damaged or missing.
Step 11: Right Rear Trailer Wheel
Dual Wheels, One or Two Axles
• Check condition of wheels and rims. Especially look for cracks, missing
lockrings, bent or broken spacers, studs, clamps or lugs.
• Check condition of tires: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stems not touching wheels, rims or
brake drums; valve caps in place and no objects stuck between the wheels.
• Check that both tires are of same type, for example, not mixed radial and
bias type and that their circumferences are matched.
• Check wheel bearing and hub: no obvious leaking on outside or inside wheel.
Suspension
• Condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
• Condition of torque rod arms.
• If equipped with sliding axles, check position and alignment. Look for
damaged, worn or missing parts, all locks present, fully in place and locked.
• Flexible air tubing not cracked, cut, crimped or otherwise damaged. Secured
against tangling, dragging and chafing.
90 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
Brakes
• Condition of brake drums. With brakes released, look for a noticeable gap
between lining and drum. (This check cannot be made if dust covers are
in place.)
• Condition of brake hoses: check for any chafing.
• Check brake chamber mounting bolts and brackets.
• With brakes applied or released, look for conspicuously different positions
of the slack adjusters.
Step 12: Rear of Trailer Area
Lights and Reflectors
• Rear clearance, identification and tail lights clean and proper color.
• Reflectors clean and proper color.
Cargo Securement
• Cargo properly blocked, braced, tied, chained, etc.
• Tailboard up and properly secured. End gates free from damage, properly
secured in stake pockets.
• Canvas or tarp (if required) properly latched down to prevent water damage,
tearing, billowing or blockage of either mirrors or tail lights.
• Rear doors securely closed, latched or locked; required security seals in
place.
• Underside guard in place: not cracked, bent or broken.
Step 13: Left Rear Trailer Wheels Area
Dual Wheels, One or Two Axles
• Check condition of wheels and rims. Especially look for cracks, lockrings
missing, bent or broken spacers, studs, clamps or lugs.
• Check condition of tires: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stems not touching wheels, rims or
brake drums; valve caps in place and no objects stuck between the wheels.
• Check that both tires are of same type, for example, not mixed radial and
bias type and that their circumferences are matched.
• Check wheel bearing and hub: no obvious leaking on outside or inside wheel.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 91
Suspension
• Condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
• Condition of torque rod arms.
• If equipped with sliding axles, check position and alignment. Look for
damaged, worn or missing parts, all locks present, fully in place and locked.
• Flexible air tubing not cracked, cut, crimped or otherwise damaged. It should
be secured against tangling, dragging and chafing.
Brakes
• Condition of brake drums. With brakes released, look for a noticeable gap
between lining and drum. (This check can not be made if dust covers are
in place.)
• Condition of brake hoses: check for any chafing.
• Check brake chamber mounting bolts and brackets.
• With brakes applied or released, look for conspicuously different positions
of the slack adjusters.
Step 14: Left Side of Trailer Area
Landing Gear or Dolly Area
• Fully raised; no missing or damaged parts.
• Crank handle present and secured.
• If power operated, no air/hydraulic leaks.
Spare Wheel(s)
• Spare wheel securely mounted in rack with no damage to rack.
• Tire and wheel condition adequate for a spare: proper size, properly inflated.
Lights and Reflectors
• Trailer side clearance lights: clean, operating and proper color.
• Reflectors clean and proper color.
Frame and Body
92 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
• Frame and crossmembers not bent, cracked, damaged or missing.
• Proper placarding.
• Body parts not damaged or missing.
Step 15: In the Cab
• Check steps and grab handles for looseness or breakage. Also, clean
them if there is any substance that makes them slippery, which makes cab
entry/exit hazardous.
• Start the engine. If equipped, check that exhaust rain cap opens when
accelerating engine.
• Check gauges and tell-tale light function. See the Instruments and Controls
section.
• Check headlights, tail lights, brake lights, emergency flashers and turn signal
lights for proper operation, cleanliness and proper color.
• Check function of low air warning.
• Check clutch function. If equipped, check for clutch brake function.
• Check windshield wipers and washers and horns, including back-up alarm,
if equipped.
• Clean inside windshield, door windows and instruments. Clean mirrors.
• Check temperature control and defroster. If equipped, check mirror heater.
• Check condition of warning triangles, fire extinguisher and flares.
• Adjust the seat. Check mirror adjustment.
• Check safety belts for function and damage.
• Apply service brakes. After initial drop, pressure should hold steady, or
increase slightly, with engine at idle.
• Check slack adjusters and chamber pushrod travel.
• Check steering wheel for excessive free play.
• Check for loose items in the cab. Secure them if necessary.
Step 16: Before Leaving the Parking Area
• Remove chocks from the wheels.
• Test trailer hook-up by slowly pulling while applying the trailer brakes with
the trailer brake hand control valve.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 93
• Test the service brakes before leaving the parking area.
• Test parking brakes by stopping on a 20% grade and applying the parking
brakes. The parking brakes shall hold the combined vehicle and trailer without
moving.
94 OPERATION
New Vehicle Break-In
To ensure many years of reliable, trouble-free operation, the following break-in
procedures are recommended:
Note: Oil change, filter change and chassis lubrication are no longer required at
the 3,000-mile vehicle break-in interval.
Refer to the preventive maintenance schedules outlined in the Maintenance
and Lubrication Manual for recommended lubrication change intervals for the
following items:
• Gear oils (transmission, rear axle carrier[s], front drive axle carrier, transfer
case, flywheel PTO)
• Engine oil
• Oil filters
• Fuel filters
• Coolant conditioner
Note: It is important that components be filled with lubricants meeting the
specifications as given in the Maintenance and Lubrication Manual (21394653)
Note: When checking oil levels, the vehicle must be parked on level ground, and
the units at normal operating temperature. Components must be filled to the correct
level. DO NOT OVERFILL.
Note: Oil and filter change intervals in this manual pertain to components built by
Mack Trucks, Inc. For information concerning oil and oil filter change intervals for
vendor components, refer to the specific vendor component service literature.
During the First 5000 Kilometers (3000 Miles)
• After the first 200 km (125 miles), retorque the wheel nuts using an accurately
calibrated torque wrench. Recheck this torque again after 800 km (500 miles).
• Check oil and coolant levels frequently.
• Check brake and clutch adjustments per recommended maintenance
schedule, and adjust as needed.
• Observe the instruments often, and shut down the engine at the first sign of
any abnormal readings.
• Report all leaks, loose fasteners, unusual noises, etc., to the service
representative at the nearest Mack dealership so they can be checked and
corrected.
OPERATION 95
• Check the spring clip torque (U-bolts). (On REYCO suspensions, also check
equalizer nut torque.)
After the First 5000 Kilometers (3000 Miles) or Before 6400 Kilometers
(4000 Miles) or Before 3 to 4 Months
• Retorque the spring clip (U-bolts). (On REYCO suspensions, also retorque
the equalizer nut.)
At the First A Inspection Interval
• Check front and rear axle alignment and adjust if the alignment is out of
specifications.
• Check steering knuckle to axle beam clearance.
Although this quality-built vehicle has been inspected, lubricated and adjusted
at the MACK Trucks Assembly Plant, an occasional air, oil or coolant leak may
develop. Quick action to correct these minor items will prevent a major repair
later. Take the vehicle to the nearest MACK service center as soon as any
abnormal condition becomes evident.
Initial Valve Adjustment Intervals
Refer to the Maintenance and Lubrication Manual (21394653) for detailed
information concerning the Initial Valve Adjustment Interval also see page 223.
96 OPERATION
WINDSHIELD WASHER RESERVOIR
As shown in the drawing below, the windshield washer reservoir opening is
located on the chassis above the rider-side step.
C0029698
OPERATION 97
CAB TILT OPERATION
DANGER
Before attempting to tilt the cab, be certain to take the following steps:
• Park on a level surface.
• Apply the parking brake.
• Place the gearshift lever in NEUTRAL position.
• Shut off the engine.
• Secure all loose items within the cab.
• Close the cab doors.
The cab is mounted on the chassis frame by two front hinges and two rear
cab locks. This arrangement allows the cab to tilt forward to a maximum of 60
degrees, exposing the engine compartment for easy accessibility.
The cab tilt system uses one hydraulic cylinder. It incorporates internal safety
valves which lock up automatically if the cab moves too rapidly in either
direction.
The hydraulic fluid pressure imbalance forces the check valves to seat,
holding the cab in a hydraulically locked position. If this situation occurs,
operate the pump in the opposite direction to open the check valves. The
system will then be returned to normal operation.
98 OPERATION
Tilting the Cab
Use the following instructions to tilt the cab:
Note: Before raising the cab, the engine must be shut off and all loose items in the
cab must be secured.
1. Take the cab tilt pump handle from its stored position.
Note: The cab tilt pump handle is stored inside the cab, on the right side cab back
wall, behind the folding seat.
2. Insert the handle into the pump and move the pump control lever (see
arrow) to the RAISE position (refer to the illustration).
C0029699
Pump Control Lever (Arrow)
OPERATION 99
3. To raise to the service position, pump the cab up to the SERVICE HEIGHT
position.
C0029700
1. Safety Prop
2. Thumb Screw
100 OPERATION
Note: In the service position, the cab must be secured with the safety prop (see
illustration).
4. To secure the cab in the service position, loosen the thumbscrew and swing
the safety prop down onto the safety prop stud (see arrow). The slot in the
safety prop should settle securely around the stud (refer to the illustration
above).
WARNING
Be certain that there are no people, tools or unsecured vehicle parts in the path
of the descending cab before shifting the pump control lever.
5. It may be necessary to manipulate the pump control lever, while the cab is
descending, so the safety prop settles on the stud.
6. To raise the cab to the full tilt position, pump the cab up past the balance
point. Note that the cab will descend by itself, although the rate of descent
may be controlled by manipulating the pump control lever from the RAISE to
LOWER position.
Lowering the Cab
Note: Before lowering the cab, the cab safety prop must be in the stored position and
the transmission must be in NEUTRAL.
1. Move the pump control lever to the LOWER position.
2. Pump until the cab is past the balance point and allow the cab to descend
and latch.
3. Leave the pump control lever in the LOWER position while the vehicle is
in operation.
OPERATION 101
Bleeding the Cab Tilt System
Note: In order to bleed the system, the cab must be in the lowered position.
Note: To perform a system bleed, the following steps must be performed in the
designated order:
1. Connect all hydraulic lines.
2. Tighten all connections (except two) at the tilt cylinder.
3. Tighten one connection at each latch cylinder.
4. Fill the pump reservoir to the top with MACK specified oil.
CAUTION
Do not refill the reservoir with the cab in the RAISE position.
5. Close and tighten the fill plug.
6. Shift the pump control lever to the LOWER position and pump until the
LOWER lines are bled; also tighten the corresponding connections.
7. Shift the pump control lever to the RAISE position and pump until the
RAISE lines are bled; also tighten the corresponding connections.
8. Bleed the latch cylinders and tighten the connections.
9. Bleed the push port of the tilt cylinder and tighten the connections.
10. After the entire system has been bled, shift the pump control lever to the
LOWER position; then check and refill the reservoir, if necessary.
Note: The recommended type of fluid for the cab tilt system is CF-A (MIL-H-5606E);
the approximate capacity is 1.4 liters (3 pints).
WARNING
The pump control lever must be in the LOWER position before operating
the vehicle.
102 OPERATION
HOSE TENDERS
C0029701
CAUTION
Avoid loose hoses. Air lines and tractor-to-trailer electrical connections must be
secured to the tractor hose tenders (hose hanger, towel bar, pogo stick, etc.) to
prevent them from tangling in the driveline.
OPERATION 103
DOORS
Standard Door Panel
C0029320
Manual Locks and Windows — Passenger Side (Right) Shown
1. Manual Door Lock
4. Storage Pouch
2. Door Handle
5. Lower View Window (Passenger
Side Only)
3. Door Light
6. Window Crank
1. Manual Door Lock — Push backward to lock. Push forward to unlock. The
lock opening appears red when unlocked.
2. Door Handle — Lift handle to open.
3. Door Light — The door light automatically comes on when the door is
opened and goes out when the door is closed.
4. Storage Pouch — Large, rigid storage pouch.
5. Lower View Window — Provides safe viewing of low lying obstacles on
construction sites.
6. Window Crank — Turn counterclockwise to open, clockwise to close.
104 OPERATION
Opening the Cab Door
The inside door handles are flush-mounted, with paddle-type design. To open
the door, grasp the handle and pull out while exerting some force on the door.
C0029618
Note: If the door is locked,pull inward on the door handle to unlock the door.
Locking the Cab Door
To lock with the door open, press the door handle inward and shut the door.
To lock with the door closed (from the inside), press inward on the door handle.
OPERATION 105
REMOTE KEYLESS ENTRY — (OPTIONAL)
This vehicle is equipped with a Remote Keyless Entry system. This system
operates by means of a hand-held remote control that locks and unlocks
the cab doors.
The remote control door lock transmitters are supplied in pairs; each one is
attached to a key ring.
C0029323
1. LED
4. Press and hold for 0.5 second to
turn external lights on or off.
2. Press once to unlock driver side
door. Press twice to unlock both
doors.
5. Press once to lock doors. Press
twice for horn confirmation.
3. Press and hold for 3 seconds to
activate panic mode. Press and hold
for 3 seconds again to cancel panic
mode.
Each transmitter is powered by a 3-volt battery and is water resistant.
Information concerning battery replacement, troubleshooting and programming
the transmitters is provided in this section.
The receiver in the vehicle is capable of recognizing four transmitters.
Replacement transmitters are available; however, they must be programmed
to match the specific receiver (refer to the "Programming the Transmitter"
section).
106 OPERATION
Transmitter Operations
The door transmitter has four buttons (labeled LOCK, UNLOCK, AUX and
HORN) to control operation of the system. When any of the buttons is
pressed, a coded Ultra-high frequency (UHF) radio signal is transmitted to
the receiver in the vehicle.
The transmitter must be within approximately 10 meters (33 feet) of the vehicle
for the receiver to detect the coded signal. The Remote Keyless Entry system
has no affect on the normal operation of the power door locks.
When the LOCK button is pressed, the doors will lock and the lights will flash
once indicating that the doors are locked. The dome light will be on for 5
seconds upon locking the door by remote. For audible confirmation of the
door lock, press the LOCK button a second time and the horn will beep once
to confirm the doors are locked.
When the UNLOCK button is pressed once, the drivers door will unlock and
the lights will flash twice indicating that the door is unlocked. The dome light
will be on for 30 seconds upon unlocking the door by remote. Pushing the
UNLOCK button a second time within 3 seconds will unlock both doors.
Note: If AUTO RE-ARM feature is selected, the keyless entry system will
automatically re-arm itself 60 seconds after the doors are unlocked with remote
transmitter. Automatic re-arm will cancel if any door is opened before the 60 seconds
timer has elapsed.
Press and hold the AUX button on the transmitter for 0.5 second to turn
perimeter or trailer access lights "On" or "Off" (if equipped).
Press and hold the HORN button on the transmitter for 3 seconds. The horn
will immediately sound and running lights will flash. During panic mode,
the normal function of this transmitter button will be suspended. LOCK and
UNLOCK buttons cannot be used to lock and unlock the doors. To stop the
alarm, press and hold the HORN button on the transmitter again for 3 seconds.
If the button is not pressed, the alarm will automatically stop after 60 seconds.
Battery Replacement
Under normal use, the transmitter battery should last approximately two years.
When battery replacement becomes necessary, use a Panasonic 3 volt, type
CR2032, or equivalent. Replace the battery as follows:
OPERATION 107
1. Open the transmitter by inserting a dime between the two halves of the
transmitter case (near the key ring hole) and twisting.
C0029324
2. Remove the battery.
3. Install a new battery with the positive (+) side down.
C0029325
1. Battery, positive (+) side down
4. Align the transmitter case halves, then snap the case together.
5. Check the operation of the transmitter.
108 OPERATION
Troubleshooting
The following checks may be used to diagnose any problems which may
arise with Remote Keyless Entry system operation. Remember to check all
transmitters.
1. Lower the windows, turn the ignition key to the OFF position and close
the doors.
2. Stand near the driver’s side door, aim the transmitter at the vehicle
and operate both functions of the transmitter. Repeat for all transmitters,
if applicable.
• If a single function on one transmitter is inoperative, replace the transmitter.
• If all functions on any of the transmitters are inoperative, reprogram
all transmitters and repeat the troubleshooting procedures. Refer to the
"Programming the Transmitter" section.
• If one transmitter cannot be programmed, replace the battery in the
transmitter. Refer to the "Battery Replacement" section.
3. If all functions on all transmitters operate, stand approximately five feet from
the vehicle (at several points around the vehicle), and check the operation of
all transmitters at each point.
• If one transmitter does not operate at some point where another transmitter
does operate, replace the battery in the transmitter that does not operate.
• If all transmitters operate approximately five feet from the vehicle, the system
is operating properly and no repairs should be attempted.
Programming the Transmitter:
1. Turn the ignition switch to the ON position.
2. Access the keyless entry module, located behind the D-Panel.
3. Push the Program switch on the keyless entry module three times. The
program LED on the module will be solid, to indicate you are now in the
Transmitter Programming Mode.
4. Press any button on one of the transmitters until the horn responds with
a chirp and the LED will flash once, to confirm the first transmitter is now
programmed.
5. If necessary, repeat Step 3 to program the 2nd, 3rd and 4th transmitters.
Note: If more than four transmitters are programmed, the system will only retain
the last four transmitters programmed.
6. To exit Programming Mode, turn the ignition switch to the OFF position, or
simply wait 15 seconds. The LED will be off to confirm exit.
OPERATION 109
Feature Programming:
1. Turn the ignition switch to the ON position.
2. Access the keyless entry module, located behind the D-Panel.
3. Push the Program switch on the keyless entry module six times. The horn
will chirp six times, and the program LED on the module will be solid, to
indicate you are now in the Feature Programming Mode.
4. Press and release the transmitter button corresponding to the feature you
want to change.
Note: The horn chirps and LED pulses will indicate the new setting.
5. Press the transmitter button again to change the feature again. Keep
pressing the transmitter button until the module advances to your desired
setting.
Press Transmitter
Button
AUX
One Chirp/LED One
Pulse Factory Default
Setting
Two Chirps/LED Two
Pulses
The Remote function
can operate with
ignition "on"
The Remote function
cannot operate with
ignition "on"
Automatic Re-Arm OFF
Automatic Re-Arm ON
External Light turns on
for 3 minutes
External Light turns on
for 5 minutes
Three Chirps/LED Three pulses = External Light
turns on for 10 minutes.
Four Chirps/LED Four pulses = External Light turns
on for 15 minutes.
Five Chirps/LED Five pulses = External Light turns
on for 20 minutes.
6. To exit Programming Mode, turn the Ignition to the "Off" position, or simply
wait for 15 seconds. The horn will respond with a short + long beep and the
LED turns off to confirm exit.
110 OPERATION
SEAT BELTS
DANGER
Seat belts should always be secured BEFORE the vehicle is set in motion.
Failure to use seat belts can result in SEVERE bodily injury or death. Unbelted
riders could be thrown into the windshield or other parts of the cab, or thrown
out of the cab entirely.
Seat Belt Operation
MACK vehicles manufactured on or after September 1, 1990 must have
locking retractable seat belts.
For all seating positions in your MACK vehicle, this type of seat belt is a
combination lap and shoulder belt.
This type of belt is designed to lock (prevent belt travel out of the retractor)
only during sudden stops or impacts. This feature allows the operator to move
freely under normal conditions. Seat belts cannot be locked by jerking on the
belt, except during sudden stops or harsh bumps.
Fastening Seat Belt
1. Pull clip so the belt crosses your shoulder and lap and insert it into the
buckle until an audible snap is heard.
DANGER
Use the shoulder belt only on the shoulder that is closest to the vehicle door.
Never wear the shoulder portion of the belt under your arm or behind your back.
Improper use will increase your chances of injury during a collision.
DANGER
To prevent possible injury the belt must be positioned low over the pelvis, below
the abdomen. If the belt is buckled too high, it will apply force to the abdomen, not
the pelvic region, and could cause serious internal injuries during a sudden stop.
OPERATION 111
DANGER
Do NOT wear seat belt loosely. Do NOT use one belt for more than one person.
2. Make sure the clip is securely fastened into the buckle.
C0029326
3. To tighten the lap portion of the combination belt, pull upward on the
shoulder portion until the lap portion fits snugly. The belt should rest as low on
your hips as possible.
Unfastening Seat Belt
Push down on the button to release the belt.
112 OPERATION
Seat Belt Maintenance
• Keep belt clean and dry.
• Clean with mild soap solution and lukewarm water.
DANGER
Do NOT bleach or dye belt, as this may cause severe loss of strength. Do NOT
install belt in a truck with a weakened floor until the floor has been replaced
or reinforced.
• Periodically inspect the following areas and replace any inadequate parts:
Buckle and Latchplate — The buckle and latchplate should mate easily
with a solid click and release easily and quickly with moderate pressure on
the release button. All metal seat belt components should be free of signs of
damage, corrosion or rust.
Webbing — The webbing should show no signs of wear, fraying or holes, and
it should be reasonably free of dirt which could find its way into the retracting
mechanism.
Retractors — The retractors should function smoothly and maintain
an appropriate amount of tension. Loose webbing is an indicator that
maintenance is needed; it’s likely that a too-loose belt will fail to tighten
properly when necessary.
Seat Belt Mounting Components — The tethering should be free of wear
and debris; the webbing should show no signs of wear, fraying or holes; and
the metal components should be free of signs of damage, corrosion or rust.
DANGER
Seat belt assemblies must be replaced after an accident if they have been
subjected to loading by occupants (even if no damage is obvious), or if they have
been damaged by an accident (bent retractor, torn webbing, etc.). If there is any
question regarding belt or retractor condition, replace the appropriate part.
OPERATION 113
Komfort® Latch System
Seat Belt Assembly
The Track III three-point seat belts installed in this chassis are designed to
provide the highest degree of operator safety, comfort and convenience.
Additional comfort is provided by the Komfort Latch mechanism, which is
incorporated into the seat belt assembly, and may be used to relieve any
discomfort caused by the constant pressure of engaged seat belts.
Seat Belt Operation
To buckle the seat belt, grasp the latch portion of the buckle, bring it across
your lap (from outboard to inboard) and insert it into the fixed buckle which is
mounted to the floor or seat (depending on seat type). With the belt properly
latched, the pelvic and upper torso restraints will be in place and automatically
adjusted to provide a snug fit.
Komfort Latch Feature
If the constant tension of the buckled seat belt causes any discomfort, engage
the Komfort Latch as follows:
DANGER
Do NOT attempt to engage the Komfort Latch feature while the truck is in motion.
Engagement — Pull the webbing of the shoulder belt away from the upper
torso, pulling only as much slack as needed while still allowing the belt to exert
slight pressure against your chest and shoulder. (Maximum amount of slack
should not exceed one inch when measured from the chest to the belt.) While
holding the slack, lift the lever located on top of the Komfort Latch mechanism
upward to clamp the webbing in place.
Normal Release — To unfasten the seat belt, simply release the buckle and
give the shoulder belt a quick tug to release the Komfort Latch mechanism.
Allow the belt to retract into the retractor.
Emergency Release — In the event of an emergency, release the seat belt
buckle. It is not necessary to release the Komfort Latch in an emergency
situation.
114 OPERATION
Note: If forward movement is required while the Komfort Latch mechanism is
latched, the latch automatically releases when you lean against the shoulder portion of
the belt. Repeat the above steps to reset the Komfort Latch, if desired, after forward
movement is no longer required.
DANGER
Excessive slack will reduce effectiveness of the seat belt, which could result in
personal injury and death. CAREFULLY follow the instructions for adjusting
the tension-relieving device.
OPERATION 115
SEAT ADJUSTMENT AND RECLINE (IF EQUIPPED)
WARNING
Do not adjust the driver’s seat while the vehicle is moving. After adjusting the
seat and before driving off, ensure that the seat is firmly latched in position.
WARNING
Do not drive or ride with the seat reclined. In case of a sudden stop, a person
in a reclined position may slide under the seat belt.
MACK ENGINE INFORMATION
For engine starting procedures, refer to “STARTING THE VEHICLE”, page
137.
Precautions and Warnings
CAUTION
If a winterfront is needed, use only a winterfront that was designed for this specific
chassis. Winterfronts are not recommended, but may be used during very cold
weather with sustained temperatures below -25°C (-13°F).
CAUTION
Be sure to avoid high intake/exhaust temperatures when using winterfronts under
normal operating conditions (above freezing). The restriction of airflow can cause
higher exhaust temperatures, power loss, excessive fan usage and reduced fuel
economy.
116 OPERATION
CAUTION
If a winterfront is used, a MACK-approved exhaust pyrometer must be installed and
closely monitored while the engine is in operation. Do NOT exceed the maximum
temperature indicated by the red line on the gauge. To reduce exhaust temperature,
downshift or reduce engine power and open the winterfront.
CAUTION
Do not permit a heavy load to drive the engine above the governed speed. Operate
in a gear low enough to allow the engine to accelerate to (or maintain) governed
speed when applying the throttle.
WARNING
Misuse or modification of a turbocharger can result in serious injury and
property damage. In addition, extreme care must be taken to avoid foreign
material induction, excessive exhaust temperatures and lack of lubrication.
CAUTION
The maximum allowable engine speed is listed on the warning label on the sun
visor. DO NOT exceed 2,300 rpm.
OPERATION 117
Engine Model Designations
The MACK engine model designation system uses letters and numbers to
provide a complete unit description.
MP Engine ID Letters and Number
C0029329
MP7 Used as an Example
1. Mack Power
3. Curve Family:
Econodyne = E
Maxicruise = C
Maxidyne = M
2. Peak Horsepower
4. Rounded Cubic Inch Displacement
118 OPERATION
CRUISE CONTROL OPERATION
Speed Control Switches
Note: Effective August 2008, a change was made to the vehicle software which
requires the vehicle operator to press and release the brake pedal after the engine
has been started. If the brake pedal is not depressed after starting the engine, cruise
control will not function.
Resume/Set Switch — Allows the driver to set and resume cruise control.
Note: In most cases, the Speed Control switch must be in the ON position in order
to use the Resume/Set switch. However, when the Initial Set Using Resume Switch
feature is enabled, cruise control can be activated using the Resume/Set switch.
The Resume/Set switch also functions as the Accel/Decel switch. Usually the
Resume position (press the top) corresponds to an increase in engine speed
(Accel) and the Set position (press the bottom) corresponds to a decrease in
engine speed (Decel).
Note: Under specific circumstances this switch can also be used to activate cruise
control. For details concerning the Initial Set Using Resume Switch feature, refer to
the V-MAC Support Software User’s Guide.
Speed Control Switch — Activates the cruise control system.
At the desired speed, press and release the Resume/Set switch. This speed
is now programmed and will be automatically maintained.
Note: To increase the engine speed, press and hold the Accel switch until the desired
speed is attained, or press the accelerator pedal until the desired speed is attained
and then press and release the Set switch.
OPERATION 119
Disengaging Cruise Control
To turn off the cruise control system, move the Speed Control switch to the
OFF position.
Note: If the Speed Control switch is moved to the OFF position, the process of setting
cruise control must be repeated in order to re-activate cruise control (unless the Initial
Set Using Resume Switch feature is enabled).
To temporarily disengage cruise control, disengage the clutch or apply the
service brakes.
Note: If cruise control is temporarily disengaged using the clutch or service brakes,
press the Resume switch to resume the previously programmed speed.
120 OPERATION
MACK POWERLEASH™ ENGINE BRAKE (IF
EQUIPPED)
Engines may be equipped to be PowerLeash™ upgradeable. These engines
will be equipped with PowerLeash™ camshaft. These engines are identified
on the engine information sticker.
If your vehicle is equipped with the MACK PowerLeash™ Engine Brake, it is
important that you take the time to become familiar with your engine brake
before putting it into operation.
WARNING
Operation of any vehicle on wet or slippery roads requires extreme caution.
Because the engine brake converts the engine to a retarding device, it should
NOT be used on wet or slippery roads if the vehicle has a single driving axle
or if it has tandem driving axles that are lightly loaded. Use of an engine
brake under these conditions can cause the vehicle to skid or a combination
vehicle to jackknife.
Engine Brake Switch
The Engine Brake switch is located on the dashboard. The Engine Brake
switch is a three-position switch located on the instrument panel.
C0029330
To operate the vehicle without the engine brake active, leave the
dash-mounted switch in the OFF position.
CAUTION
OPERATION 121
The V-MAC® system prevents engine brake activation if the oil temperature is
below 55°C (131°F). The driver should be alert to the fact that the engine brake
will not function until sufficient warm-up time has elapsed, regardless of the dash
switch setting.
How the Engine Brake is Activated
When the engine brake is "enabled" (switch in either LOW or HIGH position),
your engine V-MAC® electronic control system commands engine brake
power (engine brake "active") only when the following conditions are true:
• The foot-operated engine accelerator pedal is not depressed.
• The clutch pedal is not depressed (manual shift transmissions only).
• The engine speed is at least 900 rpm.
• Vehicle must be in gear.
• Vehicle speed should be greater than 8 km/h (5mph).
If the engine brake is active, the engine brake will automatically be deactivated
by depressing either the accelerator or the clutch, or if the engine speed drops
below 900 rpm. As soon as all of the engine brake "active" conditions are
again true (taking your foot off the accelerator, for example), the engine brake
will again be activated. In order to disable the engine brake, simply return the
dash-mounted control switch to the OFF position.
DANGER
The engine brake should never be considered a substitute for the vehicle service
brakes. The service brakes should always be maintained in good working order,
and should always be viewed as the primary vehicle slowing system. Service
brakes are always used to bring the vehicle to a complete stop.
Cruise Control with the MACK PowerLeash™
Engine Brake
When the MACK PowerLeash™ Engine Brake is enabled at the same time
your V-MAC® cruise control is in use, the engine brake automatically activates
when necessary to slow the vehicle to the cruise set point speed. You can
select one of two possible options:
• The engine brake is activated 2 mph above the cruise set point.
• The engine brake is activated as soon as cruise control commands fueling to
zero (vehicle has just reached cruise set point and fuel has been turned off).
122 OPERATION
The first option is the more popular choice for highway use and is the default
mode. Consult your V-MAC® IV Operator’s Manual for more information
about this option. Your local MACK dealer can change the current selection.
The engine brake’s ability to control maximum vehicle speed is limited
to the selected retarding power of the engine brake. If the engine brake
dash-mounted control switch is set to the LOW position, only half of the
available braking power is used. If the dash-mounted control switch is set to
the HIGH position, the cruise control invokes full engine brake power.
Note: Deactivating the cruise control function does not disable the engine brake.
The MACK PowerLeash™ Engine Brake may be activated or deactivated by
other vehicle systems such as ABS and Headway control systems. Refer to
the literature concerning these systems for additional information.
OPERATION 123
ON THE ROAD WITH THE MACK POWERLEASH™
ENGINE BRAKE
If you are not familiar with the use and operation of a heavy-duty diesel
engine brake, it is essential that you read the following section carefully. It is
very important that you take the time to gain experience with your MACK
PowerLeash™ Engine Brake in good driving conditions, before using it in
difficult or hazardous driving conditions, such as steep descents or slippery
roads. Of course, there is no substitute for driver training by a qualified
specialist.
The following information is intended as a guideline to safe and appropriate
use of the MACK PowerLeash™ Engine Brake. It is difficult to describe
every possible driving condition. Certain circumstances may require a more
conservative approach than will be described. When encountering any new
driving route or situation, err on the side of caution.
Over Flat Terrain
The LOW power position is likely adequate to control vehicle speed in
situations where the roadway is relatively flat or has modestly graded rolling
hills, and if total vehicle weight is light.
C0029331
1. High
2. Low
3. Off
124 OPERATION
As grades and vehicle weight increase, it will be necessary to use the HIGH
position.
C0029332
1. High
3. Off
2. Low
Descending a Grade
DANGER
The MACK PowerLeash™ Engine Brake assists you in establishing faster
downhill descent speeds than in a similarly configured and loaded vehicle without
an engine brake; nevertheless, even with an engine brake, there are limits to the
maximum vehicle speed at which you can travel on downhill grades and still
keep your vehicle safely under control. Always approach these situations with
caution, and gain the experience necessary for each grade and driving condition
to determine the appropriate downhill descent speed.
For a certain vehicle and load condition, a "control speed" may be established
for a given descent. The control speed is the vehicle speed at which the
retarding forces of air drag, rolling resistance and engine brake power are
equally balanced by the natural force of gravity that causes the vehicle to
accelerate down the hill, resulting in a steady, controlled vehicle speed. The
additional vehicle slowing power offered by the MACK PowerLeash™ Engine
Brake allows the driver to descend the hill in a higher gear than normal (at a
faster control speed), without overspeeding the engine.
For example, consider that you are descending a grade with a specific vehicle
and an assumed total vehicle weight. You will find that without an engine
brake, you must descend this grade in third gear to maintain a steady 10 mph
at 2,000 engine rpm, without the need to apply the service brakes.
OPERATION 125
C0029333
1. Descent Speed without MACK Engine Brake
Switch the MACK PowerLeash™ Engine Brake to the HIGH position, and now
it is possible to descend the same grade in sixth gear to maintain a steady
35 mph at 2,000 engine rpm.
CAUTION
The maximum allowable engine speed is listed on the warning label on the sun
visor. Do NOT exceed 2,300 rpm.
C0029334
1. Descent Speed without MACK Engine Brake
126 OPERATION
In any gear selection higher than sixth gear (in this example), it would be
necessary to occasionally apply the service brakes to maintain a safe vehicle
speed and to avoid overspeeding the engine.
DANGER
As with any vehicle, regular and excessive application of the service brakes
during a downhill descent can lead to a brake lining overheat condition, resulting
in a very dangerous loss of service brake retarding capability.
Note: The previous figures apply only to this hypothetical example. Specific vehicle
control speeds and engine speeds for a given descent are dependent upon the actual
vehicle and engine configurations, the gross weight of the vehicle, and the percent
grade of the road.
On Slippery Road Surfaces
As with many aspects of operating a heavy-duty vehicle, special care should
be taken when using the MACK PowerLeash™ Engine Brake on slippery road
surfaces. The potential for unpredictable loss of vehicle traction is a serious
concern; in some situations the engine brake should not be used at all.
As always, approach untested driving conditions with caution. Avoid use of the
MACK PowerLeash™ Engine Brake in these situations until you have gained
some experience under normal driving conditions.
As a rule, make sure that the vehicle is demonstrating good tractability with the
engine brake off before checking for tractability with the engine brake enabled.
Then, provided traffic conditions are safe for "testing" tractability, switch the
MACK PowerLeash™ Engine Brake to the LOW position. If the vehicle shows
any signs of loss of control (ABS activation or vehicle swerving, for example),
immediately switch the engine brake back to the OFF position.
OPERATION 127
C0029335
1. High
3. Off
2. Low
Only if the vehicle demonstrates good control in the LOW position (again, only
in safe driving conditions) should you test in the HIGH position, if desired.
Return to the LOW position and proceed with caution if there is any sign of
loss vehicle control.
Note: Always monitor vehicle tractability in slippery road conditions, and make
adjustments to engine brake switch position and vehicle speed as necessary. Always
test the LOW power position setting before moving to the HIGH position.
Your MACK PowerLeash™ Engine Brake and ABS control systems are
designed to work together for optimized vehicle control. The engine brake
function may be modified or interrupted briefly in the event of pending wheel
lock.
CAUTION
Do not enable the MACK PowerLeash™ Engine Brake during bobtail operations,
or when operating on slippery roads with an empty or lightly loaded trailer.
128 OPERATION
BRAKE OPERATION
Air Brake System
This chassis features a dual braking system which has two complete air
circuits: a primary circuit for rear brakes and a secondary circuit for front
brakes. Each circuit receives air from separate reservoirs. Although there are
two air circuits, they operate as one brake system through the dual-circuit
treadle valve. This provides the driver with easy, graduated control when
applying and releasing the brakes.
The air pressure in the two circuits is monitored by gauges on the instrument
panel. When air pressure drops below 517 ± 34 kPa (75 ± 5 psi) in either
system at any time other than vehicle startup, pull to the side of the road and
determine the problem. If air pressure continues to drop below 40 ± 5 psi in
BOTH systems, spring brakes will automatically apply. The Low Air Pressure
Warning indicator and buzzer will be activated if low air pressure occurs
in either circuit.
In tractor applications, the Trailer Supply Valve (red octagonal knob) will
immediately pop out in the event of a trailer breakaway or sudden trailer air
line failure, which will apply the trailer spring brakes. In the event of a slow
leak in the trailer air system, the trailer supply valve will pop out when system
Pressure reaches 60 psi. This protects the tractor air system from further
pressure loss.
If the Trailer Supply Valve is held in, in an attempt to override application of
the trailer spring brakes, the Park Brake Valve (yellow diamond knob) will
automatically pop out and apply the parking brakes when system pressure
drops to approximately 20–30 psi.
The air brake system consists of three main elements:
• The compressor, governor and reservoirs supply and store the air pressure.
• The brake application valve controls the brake application pressures.
• The brake chambers control the brake mechanism.
Air Brake Operation
CAUTION
Avoid sudden stops. Constant, sudden stops may negatively affect the performance
of braking and driving parts.
OPERATION 129
When slowing for a stop, leave the clutch engaged for as long as possible to
use the braking effect of the engine. When forward speed has dropped to a
little above idling speed, push clutch pedal in and brake to a complete stop.
Automatic Slack Adjusters
Automatic slack adjusters are designed to automatically maintain proper brake
chamber pushrod travel and compensate for brake lining wear during normal
use. Manual adjustment of an automatic slack adjuster should never be
performed except when performing brake or wheel service (such as backing
off the brake shoes for wheel removal, brake shoe relining/replacement, brake
drum reconditioning, etc.).
When pushrod travel exceeds specifications (as given in the "BRAKE
ADJUSTMENT" section of the Maintenance and Lubrication Manual,on a
vehicle equipped with automatic slack adjusters, a mechanical problem with
the slack adjuster, brake components or improper installation of the slack
adjuster is indicated. If brakes are found to be out of adjustment, the vehicle
must be taken to the nearest repair facility to have the problem investigated
and corrected.
DANGER
Automatic slack adjusters should not be manually adjusted in an effort to correct
excessive pushrod stroke, because this condition indicates that a problem exists
with the automatic adjuster, with the installation of the adjuster, or with related
foundation brake components, which manual adjustment will not fix. Manual
adjustment of automatic slack adjusters is a dangerous practice that could have
serious consequences, because it gives the operator a false sense of security
about the effectiveness of the brakes, which are likely to go out of adjustment
again soon.
Parking Brake System
Spring-type parking brakes are standard on all single and tandem rear axles.
The spring brake system consists of an air cylinder with heavy springs, which
is integrated with the spring brake air chamber. When there is no pressure in
the air chamber, the springs expand (causing a brake application). When air
pressure is applied to the air chamber, the springs are compressed (releasing
the brakes).
130 OPERATION
Parking Brake Operation
The parking brakes can be applied and released from the cab, using the
hand-operated push/pull control valve with the yellow diamond knob.
In the event of a significant air pressure loss in both the air brake systems,
the spring brake air chambers will be automatically exhausted (applying the
brakes). The parking brakes will remain applied until enough pressure is
available to recompress the springs.
Parking
WARNING
• NEVER use the trailer parking brake system alone.
• NEVER use the tractor parking brake system alone.
• ALWAYS use the tractor and trailer parking brake systems together.
• ALWAYS apply the parking brakes when parking and make sure the parking
brakes are holding the vehicle from moving before leaving the driver’s seat.
• When parking on a grade, use wheel chocks under the rear wheels or turn
the front wheels to the curb. Do not leave diesel engine vehicles in gear; if the
vehicle should move, the engine may start by heat of compression.
• Check brake adjustment frequently to be sure that the brakes will lock and
hold the vehicle when parked.
• Do not use the parking brake to slow or stop the vehicle when in motion,
except in an emergency.
• Do not use hand control valve for parking.
Anti-Lock Brake System (ABS)
Note: Anti-lock brake systems became mandatory in the U.S.A. on all tractors
beginning March 1, 1997; all trucks beginning March 1, 1998, and all trailers
beginning March 1, 2001. Federal regulations require that any tractor/truck with a
trailer air connection built beginning March 1, 2001 must have a data communications
link with the trailer ABS and an indicator lamp located in the cab to alert the driver if
there is a trailer ABS malfunction.
ABS Operation
When operating an ABS-equipped vehicle, the following guidelines should
be used.
OPERATION 131
• Apply the brakes as normal. If the anti-lock brake system begins to function,
maintain brake pressure. Do NOT release the brakes.
• Avoid rapidly pumping the brakes. The anti-lock brake system automatically
applies and releases the brakes up to five times per second.
• When towing a trailer, watch the trailer through the mirrors. Adjust brake
application as necessary to keep the combination in a straight line. Make sure
the trailer follows the tractor properly.
• An amber trailer ABS lamp on the instrument panel will illuminate for several
seconds at start-up during an initial function check. When a trailer ABS fault
occurs, the lamp will remain illuminated until the fault is cleared. If there is
a loss of communication between the tractor and trailer, the lamp will blink
three times. Refer to “Anti-Lock Brake System (ABS)”, page 130 for more
information.
MACK Road Stability Advantage (If Equipped)
The MACK Road Stability Advantage (RSA) is based on the Bendix® ABS-6
Advanced with ESP® (Electronic Stability Program) System. The RSA system
aids the operator in maintaining control of the vehicle in the event of a
jackknife or rollover situation by applying select brakes and reducing engine
power as required by the specific situation. The RSA system, which is integral
with the anti-lock brake system, uses the standard ABS components (such
as wheel speed sensors and modulator valves) along with a Steering Angle
Sensor (SAS-60™) and a Yaw Rate/Lateral Acceleration Sensor (YAS-60™)
package to provide information concerning vehicle movement to the Advanced
EC-60™ Electronic Control Unit.
In most cases, vehicle repairs will not affect function of the MACK RSA
system. However, the following repairs require recalibration of the SAS-60™
sensor after the repair has been made:
• Removal and reinstallation or replacement of the SAS-60™ sensor
CAUTION
Installation of an aftermarket steering wheel may damage the SAS-60™ sensor.
It is therefore recommended that the OEM steering wheel NOT be replaced with
an aftermarket wheel.
• Any repairs to the steering system or front suspension such as:
— Replacement of front springs
— Replacement of king pins or bushings
132 OPERATION
— Replacement of the steering gear
— Replacement of the drag link, cross steering tube or ball sockets
— Replacement of the front spring hangers
— Replacement of the steering column
• Front end alignment
• Disconnecting the steering column from the steering gear, or the steering
linkage from the steering gear
WARNING
Failure to recalibrate the steering angle sensor after performing any of the
repairs mentioned above, may affect proper function of the RSA system,
resulting in a loss of vehicle control due to system intervention at inappropriate
times.
Vehicle Modifications
Alterations to the vehicle, such as changes to the wheel base (either
lengthening or shortening), the addition of an auxiliary lift axle or removal
of a factory-installed auxiliary lift axle, or major body changes, such as
conversion of a tractor to a truck or an axle, suspension or steering system
component modification, are NOT allowed, as these changes will adversely
affect performance of the road stability system. Should such changes be
unavoidable, the system must be disabled by having a qualified technician
replace the Advanced EC-60™ ECU with a Premium EC-60™ ECU.
WARNING
Failure to disable the RSA system on a vehicle that has been modified
will result in serious vehicle braking and performance issues, including
unnecessary system interventions. These interventions could lead to a loss of
vehicle control.
In addition to disabling the system, any cab labels, such as warning and
caution labels relating to the Bendix® ABS-6 Advanced with ESP® system
located on the sun visor must be removed, and notations must be made to the
operators manuals so that the vehicle operator has a clear understanding as
to which ABS options are installed on the vehicle.
OPERATION 133
Location of the yaw rate/lateral acceleration sensor must not be altered.
When servicing is required, the sensors must be replaced with identical
components using the original equipment mounting brackets and tightening
torque specifications (20 N.m [15 lb-ft]).
The following additional changes MUST NOT be made to an "as-built" vehicle:
• Changes to maximum steering angle (to the left or right)
• Changes to steer axle and/or drive axle track width
• Changing the front and/or rear brake drums to drums having a different
flange thickness
Tire Size Calibration
The ECU requires a precise rolling circumference ratio between the front steer
axle and the rear drive axles for optimum performance of the system. For
this reason, the system continuously calculates the precise ratio and stores
the information in the ECU memory.
CAUTION
Effectiveness of the RSA system relies on the accuracy of the reported vehicle
speed. If major changes to tire sizes are made, such that changes to the vehicle
speedometer/odometer settings are required, the Advanced EC-60™ ECU must be
reprogrammed with the new values by a qualified technician.
Precautions When Installing Electrical Equipment
Connecting electrically powered or electrically controlled equipment to the
vehicle may cause interference with other vehicle components (e.g., the ABS
system). The amount of interference will depend on the operating frequency
of any new signals and the degree to which transient signals are coupled
into the vehicle system.
Note: Whenever new electrical equipment is installed, it is the obligation of the
installer to ensure that the new equipment does not interfere with the proper operation
of all other electrical systems on the vehicle.
If new electrical equipment is installed, a vehicle checkout procedure should
be performed.
1. Perform the checkout procedure under the following conditions:
• Engine running
134 OPERATION
• Brake system air pressure in operating range
• Vehicle stationary
• Brake pedal fully depressed
2. Operate the new equipment under all starting, running and shutdown
conditions.
3. Listen for signs of air exhausting from ABS modulator valves (which is an
indication of an interference condition).
4. Correct all interference conditions before operating the vehicle.
Note: The center pin of the standard seven-pin trailer electrical connector has been
standardized as the dedicated connection for uninterrupted power for trailer ABS. This
pin is always hot when the tractor ignition is turned on.
DANGER
Some trailers manufactured prior to the trailer ABS regulations may use the
center pin to power certain trailer auxiliary equipment. The possibility exists that
this auxiliary equipment may be unexpectedly activated by the truck or tractor
electrical system, resulting in personal injury or damage to equipment. Caution
must be used when connecting the trailer electrical connector to ensure that
power to the center pin will not unintentionally activate any trailer auxiliary
equipment.
Automatic Traction Control (ATC) (If Equipped)
Automatic Traction Control (ATC) provides improved traction on slippery
surfaces by reducing wheel spin. The system operates automatically as
follows:
• If a drive wheel starts to spin, ATC applies air pressure to the brake of the
spinning wheel. Doing this transfers engine torque to the wheels that have
better traction.
• If all drive wheels are spinning, ATC limits engine torque which, in turn,
reduces wheel spin to provide improved traction.
When ATC automatically becomes active, the ATC indicator lamp turns on to
alert the operator. The lamp turns off when the wheel(s) stops spinning.
Heavy Mud/Snow Function (If Equipped)
ATC may also include a heavy mud/snow function which allows the operator to
activate ATC when additional traction is needed. This function is activated with
OPERATION 135
the ATC mode switch which is located on the dashboard. The heavy mud/snow
function increases available traction by increasing permissible wheel spin.
When the operator selects the heavy mud/snow function, the ATC indicator
lamp blinks continuously. The ATC lamp stops blinking when the ATC mode
switch is turned off.
The instrument cluster also contains an ABS tell-tale lamp, which indicates
when there is a problem being reported by the Trailer ABS system.
136 OPERATION
GOOD DRIVING HABITS
Weight Ratings
Do not overload the vehicle. The gross vehicle weight rating (GVWR) and
gross axle weight ratings (GAWR’s) for a given model may vary due to the
tires, wheels/rims, suspensions, axles and/or frame of a specific vehicle. For
safety and durability reasons, do not exceed the GVWR and GAWR’s listed on
your vehicle’s Safety Certification Label.
Instruments
Glance at the instruments frequently. When problems develop, take prompt
steps to correct them.
Shutting Down the Engine
After a hard run, allow the engine to idle three minutes before shutdown to
stabilize the temperature of all engine parts. Quick shutdowns can cause
engine damage and prevent the turbocharger from being properly lubricated.
For additional options, see “Shutting Down the Engine”, page 141.
General Observation
Make it a habit at stops to walk around your truck and look for fuel, oil and
coolant leaks. Also check the condition of tires, wheel nuts, springs and lights.
Stop trouble before it stops you!
OPERATION 137
STARTING THE VEHICLE
General Information
Before putting the key in the ignition switch, set the parking (spring) brake,
disengage the clutch (if equipped) and put the transmission in NEUTRAL.
CAUTION
Do not engage the starting motor too soon after an incomplete start of the engine,
or the starter may be damaged. Wait at least five seconds before attempting to
restart the engine.
CAUTION
If the engine does not start immediately, limit cranking periods to 30 seconds to
avoid overheating and damaging the starter.
CAUTION
Do not rev the engine at start-up. Turbocharger damage may result because
lubricants need time to establish a film between moving parts.
Push Button Starters
Put the key in the ignition switch. Turn the key clockwise to the first "click"
(about two o’clock position) to activate the instruments. Depress the starter
button and release as soon as the engine starts. Keep the clutch (if equipped)
disengaged until the engine runs smoothly.
138 OPERATION
Air Starters
On chassis equipped with an air starter, make sure that the air pressure gauge
reads a maximum of 120 psi before shutting down and parking for the night.
This will ensure sufficient air pressure for restarting the engine.
WARNING
Make sure clutch is depressed and transmission is in neutral before engaging
the starter! Failure to do so could cause the vehicle to jerk forward
unexpectedly causing serious damage or bodily harm.
Starting MP Engines
Use the following procedure:
1. Crank the engine until it starts.
Note: Do NOT apply the throttle pedal during engine cranking.
CAUTION
DO NOT engage the starting motor too soon after an incomplete start of the engine,
or the starter may be damaged. Wait at least five seconds before attempting to
restart the engine.
If the engine does not start immediately, limit cranking periods to 30 seconds to
avoid overheating and damaging the starter.
DO NOT rev the engine at start-up. Turbocharger damage may result. Lubricants
need time to establish a film between moving parts.
2. After the engine has started, warm the engine until the coolant temperature
reaches normal operating range (77°C to 107°C; 170°F to 225°F). Once the
engine reaches this temperature, it can be operated in a normal fashion.
Note: Warm-up time can be reduced by increasing engine idle speed between 1000
and 1200 rpm by either applying the throttle pedal or by using the Electronic Hand
Throttle feature (if equipped).
Note: For bobtail or unloaded applications, the engine may be warmed up by moving
the vehicle with "light" throttle application after only one minute of idle.
OPERATION 139
Priming the MP Fuel System
DANGER
Before working on or inspecting a vehicle, set the parking brakes, place the
transmission in neutral and block the wheels. Failure to do so can result in
unexpected vehicle movement and can cause serious personal injury or death.
DANGER
To avoid potential fire hazard, do not service any part of the fuel system while
smoking or in the presence of flames, sparks or hot surfaces, or when working on
an operating engine. Failure to follow these precautions can result in fire. To
guard against burns from direct contact with hot fuel, wear adequate protective
clothing (face shield, heavy gloves and apron, etc.) when working on a hot engine.
WARNING
DO NOT work near the fan with the engine running. The engine fan can
engage at any time without warning. Anyone near the fan when it turns on
could be seriously injured. Before turning on the ignition, be sure that no
one is near the fan.
1. Unlock the hand primer pump by pushing the pump handle in and turning it
counterclockwise.
C0029336
2. Pump the hand primer until the force of pumping increases.
140 OPERATION
C0029337
Note: When the fuel system is empty, 200 or more pump strokes may be needed
to properly prime the system.
Note: There are NO bleed nipples to be opened in order to prime the fuel system.
3. Lock the hand primer pump by retracting it into the housing and turning
it clockwise.
4. Start the engine and run it at an increased idle speed for approximately 5
minutes to remove any remaining air in the system.
5. Check the fuel system for leaks.
Note: If the engine does not start following this procedure, contact your local MACK
dealer.
Engine Warm-Up
CAUTION
Idling the engine unnecessarily for long periods of time wastes fuel and fouls
injection nozzles. Unburned fuel causes carbon formation and oil dilution. NEVER
race an engine during warm-up.
Engine damage can occur if the engine is not warmed up to a minimum
operating temperature of 77°C (170°F) before putting the vehicle into full
operation.
Heavy-duty diesel engines are designed to operate at optimum efficiency
when they are running loaded at (or very near) normal operating temperature,
where efficient combustion takes place. When the engine is operated
OPERATION 141
unloaded, lightly loaded (i.e., stop-and-go operations, PTO operations, or
periods of extended engine idling) or in cold weather conditions, normal
operating temperature may not be achieved or maintained. As a result, carbon
and/or varnish build-up will occur and lubricating oil will become contaminated
with combustion by-products.
Cold weather operations place added demands on a diesel engine. When
operating in cold climates (particularly in stop-and-go operations, PTO
operations or periods of extended engine idling), minimum operating
temperature must be maintained to prevent engine damage resulting from
valve varnishing and carbon build-up.
Note: Many accessories are available for cold weather operations. Refer to the
Maintenance and Lubrication Manual for additional information concerning cold
weather accessories.
Engine Idling
Idling the engine unnecessarily for long periods of time wastes fuel, fouls
injector nozzles and can lead to valve carbon and varnish deposits. Unburned
fuel causes carbon formation and oil dilution. Shut the engine down when
prolonged loading or unloading of cargo is required.
When starting a cold engine, or if the vehicle has been parked and the engine
coolant has fallen well below normal operating temperature, a fast idle speed
of approximately 1200 rpm should be maintained to help the engine warm
up more quickly.
Shutting Down the Engine
Standard Shutdown
After a hard run, allow the engine to idle three minutes before shutdown in
order to stabilize the temperature of all engine parts. Quick shutdowns can
cause engine damage and prevent the turbocharger from being properly
lubricated.
142 OPERATION
CAUTION
Operating the engine below normal operating temperature for extended periods of
time will allow varnish/carbon deposits to build up on the valve stems and guides.
This will cause the valves to stick in the guides after the engine has been shut down
and could result in push rod damage when the engine is restarted. If the engine
has been operated below normal operating temperature for an extended period of
time (and the odor of raw diesel fuel is detected or unburned fuel can be seen at the
exhaust stack), the engine should be operated under "load" until normal operating
temperature is achieved BEFORE shutting down the engine.
On chassis equipped with an air starter, make sure that the air pressure gauge
reads a maximum of 120 psi before shutting down and parking for the night.
This will ensure sufficient air pressure for restarting the engine.
V-MAC IV Shutdown Option: Idle Cooldown
This feature provides a means of cooling down the engine and turbocharger.
If the idle cooldown option is enabled using VCADS Pro MACK Support
Software and the system senses that the turbocharger may be hot, the engine
will not shut down when the vehicle stops, the parking brake is set and the
key switch is turned to the OFF position. This feature allows the driver to lock
the truck and walk away while still providing adequate cooldown. All switched
accessories will then turn off once the engine has stopped. If this option is
set, the engine can be shut down immediately by cycling the key switch or by
pressing the shutdown override switch.
The idle cooldown timer is set to 3.5 minutes as soon as the engine load
exceeds 25%, provided that the engine has been running at least 60 seconds.
After the load drops below 25%, the timer begins counting down. If the key
switch is turned off before the timer expires, the engine will continue to run
until the timer reaches zero.
If a pyrometer is installed, the idle cooldown function will use the pyrometer
reading, shutting the engine down when the temperature drops below 232°C
(450°F), or after 3.5 minutes, whichever comes first.
The default for this option is set at OFF from the factory.
Note: The parking brake must be on for the idle cooldown function to work.
Engine Shutdown System (If Enabled)
OPERATION 143
The engine is protected by a system that prevents engine damage by shutting
down the engine whenever a potentially damaging condition (such as loss of
oil pressure, loss of coolant or engine overheating) is detected. If the system
detects such a condition, a warning indicator light and an alarm will alert the
driver before the engine actually shuts down. Pressing the Shutdown Override
Switch on the instrument panel shortly after the vehicle sounds the engine
shutdown alarm, allows 30 additional seconds of operation. This process can
be repeated several times to safely park the vehicle.
CAUTION
Continuously overriding the shutdown system may result in severe engine damage.
Engine Shutdown Indicator — During normal operating conditions, this
indicator should illuminate as soon as the key switch is turned on. After the
engine is started, it will remain illuminated until engine oil pressure reaches
normal idling range. During shutdown, if the system detects a condition that
could lead to engine failure, the Engine Shutdown indicator will illuminate prior
to engine shutdown.
144 OPERATION
COLD WEATHER OPERATION
DANGER
Do NOT, under any circumstances, use starting fluid (ether) on engine whether or
not equipped with an inlet manifold air heater element. An explosion can occur.
Cold Weather Starting Tips
• Save the batteries. Do not overtax the batteries by cranking the starter for
more than 30 seconds without interruption. Allow about two minutes between
attempts at starting the vehicle; this allows the starter to cool and the batteries
to re-energize.
Note: Always make sure that the battery is fully charged in cold weather.
• Use the correct grade of oil for the prevailing winter temperature.
• Drain the fuel tanks and filters regularly to prevent water accumulation in the
fuel system. This accumulation can freeze in fuel tanks, fuel lines and filters.
WARNING
Do NOT — under any circumstances — add gasoline, alcohol, used oil or
additives with metallic particles to the fuel.
• If the fuel gels and starts clogging filters and small passages, mix a small
percentage of No. 1K fuel (kerosene) with Ultra-Low Sulfur (15 ppm max)
No. 2D (diesel) fuel.
Note: Adding kerosene is NOT recommended for general use because both
performance and fuel economy will be reduced.
• Refer to the Maintenance and Lubrication Manual for additional cold weather
operating information.
OPERATION 145
Engine Block Heaters
An engine block heater works by heating the coolant surrounding the
combustion chambers. Engine heaters are recommended to help combat the
extreme demands of cold weather operating conditions. When the temperature
drops, the engine heater can be plugged in overnight. The location of the
engine heater power receptacle varies according to vehicle design.
C0029338
1. Engine Block Heaters
Engine Heater Benefits
• Eliminates cold weather starting problems.
• Increases engine life significantly by keeping the engine warm and avoiding
costly, excessive idling.
• Prevents external water leaks caused by excessive cold.
• Allows the cab to heat more quickly.
• Allows the engine heaters to be activated as soon as the engine is stopped.
146 OPERATION
Winterfronts
A winterfront, although not recommended, may be used during cold weather,
with sustained temperatures below -25°C (-13°F), to aid the engine in reaching
and maintaining engine coolant temperatures within the normal operating
range.
CAUTION
Use a winterfront designed for the specific chassis. Restricted air flow through the
charge air cooler can cause higher exhaust temperatures, power loss, excessive fan
usage, reduced fuel economy and possible engine or charge air cooler damage.
The use of any other type of device, such as a radiator cover, cardboard or similar
material, is not approved by Mack Trucks, Inc.
Note: The minimum operating temperature is 77°C (170°F).
If a winterfront is used, a MACK-approved exhaust pyrometer must also be
installed and closely monitored while the engine is in operation.
CAUTION
DO NOT exceed the maximum exhaust temperature listed on the pyrometer decal.
To reduce exhaust temperature, open the winterfront, downshift or reduce engine
power.
OPERATION 147
Refer to the following chart for suggested temperature ranges concerning the
use of various cold-weather accessories.
Expected
Sustained
Coldest
Ambient
Temperature
Range
4°C (40°F)
0°C (32°F)
-7°C (20°F)
-12°C (10°F)
-18°C (0°F)
-23°C (-10°F)
-25°C (-13°F)
-35°C (-30°F)
-40°C (-40°F)
Winterfronts
Prohibited
Belly Tarp
Prohibited
Available
Suggested
Can be Used
Recommended
CAUTION
Winter treatments are NOT RECOMMENDED for vehicles which only operate
intermittently in cold climates. Sustained temperatures must be below -25°C
(-13°F).
For more information on winterfronts, please refer to the Maintenance and
Lubrication Manual .
148 OPERATION
COUPLING A TRAILER
1. Position the tractor directly in front of the trailer.
2. Back the trailer slowly until the fifth wheel just contacts the trailer plate.
3. Place the transmission in neutral and apply the parking brakes.
4. Connect the trailer glad hands and electrical connector.
CAUTION
Make sure the trailer air lines and the trailer electrical cord are properly supported
so they will not be pinched or caught while the tractor is being backed under the
trailer.
5. Check that the fifth wheel height matches the height of the underside of
the trailer. If the trailer is too high, use the landing gear to lower the trailer
until fifth wheel and trailer height match. If the vehicle is equipped with an air
suspension and the trailer is too low, use the air suspension control switch
to exhaust air from the suspension air bags until fifth wheel and trailer height
match.
CAUTION
Failure to match fifth wheel height with trailer height will result in the trailer being
improperly connected.
6. Back under the trailer slowly until the trailer king pin engages. Back slowly
to avoid hitting the king pin too hard, and stop as soon as the king pin is
locked into the fifth wheel.
7. If equipped with an air suspension, use the air suspension control switch
to reinflate the suspension air bags.
8. Raise the trailer landing gear slightly off the ground.
9. With the trailer parking brakes applied, pull the tractor ahead slightly to
ensure that the trailer is locked onto the tractor.
10. Push the trailer air supply valve (red octagonal knob) in to supply the trailer
system with air pressure. With the air system at normal operating pressure,
check the trailer air brake system for excessive leakage and proper operation.
OPERATION 149
11. Inspect the coupling to ensure the trailer is properly connected. Make
sure there is no space between the fifth wheel and the trailer plate and that
the fifth wheel jaws have closed around the shank of the king pin. Check
that the locking lever is in the "lock" position and make sure the safety latch
is in position over the locking lever.
12. After ensuring that the trailer is properly connected, raise the landing
gear to its maximum height.
13. If wheel chocks were placed at the trailer wheels, remove the chocks
and store.
CAUTION
If equipped with an air suspension, do NOT operate the vehicle with the suspension
air bags deflated. Always reinflate the suspension air bags after coupling or
uncoupling a trailer.
150 OPERATION
UNCOUPLING A TRAILER
1. Park the tractor/trailer combination on a level surface. Make sure the
parking surface will support the weight of the trailer, and make sure that the
tractor is lined up straight with the trailer. Pulling out from under a trailer at an
angle may damage the landing gear.
2. Pull the trailer air supply valve (red octagonal knob) out to apply the trailer
parking brakes.
3. Back the tractor slightly to ease pressure on the fifth wheel jaws. Apply
the tractor parking brakes while still backing against the king pin so the
combination will be held with pressure off the fifth wheel jaws.
4. Block the trailer wheels to prevent the trailer from moving.
5. Lower the trailer landing gear until the gear makes firm contact with the
ground.
6. Disconnect the glad hands and the trailer electrical connector. Connect the
glad hands to the dummy couplers at the back of the tractor and install the
trailer electrical connector into the receptacle provided at the back of the cab.
CAUTION
Make sure the trailer air lines and electrical cord are properly suspended so they
will not become tangled or damaged while the tractor is being driven.
WARNING
Keep legs and feet clear of the tractor rear wheels to avoid serious injury
should the vehicle move when the fifth wheel is unlocked.
7. Unlock the fifth wheel.
8. Pull the tractor ahead slightly (approximately twelve inches) so that the king
pin disengages the fifth wheel jaws.
9. If equipped with an air suspension, use the air control switch to exhaust
the air from the suspension air bags.
10. Pull the tractor ahead until the fifth wheel is out from under the trailer. Stop
the tractor with frame under the trailer. This prevents the trailer from falling
should the landing gear collapse or sink into the ground.
11. Place the transmission in neutral and apply the parking brakes.
OPERATION 151
12. Inspect the parked trailer to make sure the ground is supporting the trailer
and the landing gear is not damaged.
13. If equipped with an air suspension, use the air suspension control switch
to reinflate the suspension air bags.
14. Release the parking brakes and drive the tractor forward until the tractor
is clear of the trailer.
CAUTION
If equipped with an air suspension, do NOT operate the vehicle with the suspension
air bags deflated. Always reinflate the suspension air bags after coupling or
uncoupling a trailer.
152 OPERATION
MOVING THE VEHICLE — GENERAL
INFORMATION
Braking
Avoid sudden stops. Constant sudden stops may negatively affect braking
performance and driving parts. When slowing, leave the clutch (if equipped)
engaged as long as possible to use the braking effect of the engine.
CAUTION
When using the braking effect of the engine, final gear selection is critical. If gear
selection is too high, the vehicle will buck which could cause loss of control.
Shifting
Operate in a gear low enough to allow the engine to accelerate to (or maintain)
governed engine speed when applying full throttle. Allowing the engine to lug
causes excessive strain on the engine, which could damage pistons, rings,
cylinder walls, or bearings. However, be sure not to overspeed the engine.
DANGER
Always select the proper gear ratio BEFORE descending a grade (to avoid a
runaway vehicle and to stay within safe and legal speed limits). Do NOT coast
down hills. Gear ratios should be selected to allow the engine to operate between
peak torque and rated speed.
CAUTION
Do not permit a load to drive the engine above governed speed. When descending
steep grades, use lower gears and watch the tachometer. Overspeeding will cause
severe drivetrain damage and eventually destroy the engine.
CAUTION
OPERATION 153
Running the engine at a speed that is too low for the load (or grade of the road) can
cause damage to the drivetrain.
Shifting at the proper time will result in increased fuel efficiency, as well as a
decrease in costly repairs. Remember that once the engine falls below peak
torque, both torque and horsepower will drop off very rapidly. Before this
happens, downshift to the next lower gear.
For vehicles with transmissions that have extreme reduction gearing coupled
with high rear-axle loads, a torque-limiting device should be used. This device
limits the amount of fuel that can be delivered to the engine and prevents
overloading of drivetrain components while in extreme reduction gears.
Always use the same gear going downhill as uphill. This will reduce brake
wear and prevent damage to the engine from overspeeding.
Engine Temperature
Before entering high-speed traffic conditions, allow the engine to reach normal
operating temperature. A normal operating range is between 77°C and 104°C
(170°F and 220°F) for stationary vehicles.
Clutch (If Equipped)
To avoid shock damage, release the clutch pedal smoothly, without
shock-loading the driveline (especially on grades while carrying heavy loads).
Do not ride the clutch pedal. Premature wear of the clutch facing and release
bearing may result.
CAUTION
Always use the lowest drive gear combination to start the vehicle moving to avoid
premature clutch failure.
1. To move the vehicle, start the engine and wait until it reaches operating
temperature.
2. Disengage the clutch by pushing the pedal to the floor.
3. Shift the transmission into first or LO gear (see "Transmission Shifting
Instructions" for specific procedures).
4. Release the parking brake.
154 OPERATION
CAUTION
If the Parking Brake indicator is on, do NOT attempt to move the vehicle because
driveline damage may result.
5. Engage the clutch smoothly by allowing the clutch pedal to come up slowly.
For comfortable starts, do not apply the accelerator until the clutch begins to
engage.
CAUTION
Never allow your foot to ride the clutch pedal when the clutch is engaged. This will
cause premature failure and increased clutch wear.
6. As the vehicle gains speed, continue shifting until the transmission is in the
highest gear possible (with engine in operating range).
Note: When the vehicle is equipped with a torque-limiting device, the engine must be
warmed up to operating temperature before attempting to move in either REVERSE
or LO-LO range.
Clutch Brake Operation
The clutch brake is designed to stop the rotation of the transmissions input
shaft while the truck is standing still. This makes shifting into first or reverse
gears easier. Inadvertent use of the clutch brake will make shifting from a
gear difficult (i.e., shifting from reverse with the clutch brake applied and the
vehicle is stationary).
OPERATION 155
C0029340
1. Normal Clutch Pedal Travel
2. Depress Pedal Last One Inch to
Engage Clutch Brake
1. With the vehicle standing still, apply the clutch brake by pushing the clutch
pedal all the way to the floor; the clutch brake is applied when the clutch pedal
is fully depressed (the last one inch of travel past normal pedal travel).
Note: When the clutch is disengaged, a slight but definite resistance to clutch pedal
downward travel will be felt in the last one inch.
2. Shift the transmission into first or reverse gear, engage the clutch and
accelerate. The clutch brake is only to be used when the vehicle is stopped
and is shifted into first or reverse gears. It is not designed to be used as an
upshifting aid.
CAUTION
Clutch brake damage may result if used while the vehicle is in motion. The clutch
brake must NOT be used when making a downshift or an upshift.
Double-Clutching
Double-clutching is a way to bring the speed of the transmission gears into
synchronization so that the shift can be made without a clash. The engine is
156 OPERATION
used to speed up the countershaft for a downshift and to slow it down for an
upshift.
Note: For all nonsynchronized transmissions, double-clutching is necessary on
downshifts and upshifts. It is advisable to use the torque-limiting clutch brake to
engage first and REVERSE gears and to double-clutch for gear ratio changes.
1. Depress the clutch pedal and shift to NEUTRAL.
2. Release the clutch pedal and increase (downshift) or decrease (upshift)
engine speed until it roughly corresponds to the road speed of the desired
gear.
3. Depress the clutch pedal and complete the shift. Then release the clutch
pedal.
OPERATION 157
POWER TAKE-OFF (PTO) OPERATION
If the vehicle is equipped with a Power Take-Off (PTO) unit, be sure to read
the following section.
PTO Precautions
DANGER
Power Take-Off (PTO) units and related equipment can be very dangerous. Any
PTO installation, repair or replacement should include a warning indicator light
which indicates PTO engagement. The light must be located close to the PTO
control and clearly visible to the operator.
DANGER
PTO units are driven by engine or drivetrain components (flywheel, crankshaft,
transmission). Do not attempt to service the PTO and related units unless the
engine is shut down.
DANGER
Always keep body parts and loose-fitting clothing out of the range of drivetrain
components, or personal injury may result.
DANGER
Always be aware of the current PTO status (engaged or disengaged) and the
position of the vehicle body (dump body controlled by PTO, etc.). Be sure to
disengage the PTO when not in use.
DANGER
On an MP7 engine equipped with Front Engine Power Take-Off (FEPTO), the
torque limit is 385 N.m (284 lb-ft).
158 OPERATION
PTO Classification
Rear-mounted PTO units, for MACK transmissions, are categorized according
to operation.
Intermittent Service — The PTO unit is operated, under load, for less than
seven minutes and then allowed to cool before it is operated again.
Note: If a PTO unit is operated for less than seven minutes but is "not" allowed to
cool down before operating again, it is considered in Continuous Service.
Continuous Service — The PTO unit is operated, under load, for seven
minutes or more.
Note: Rear-mounted PTO units operating under the Continuous Service guideline
must not be run at more than 70% of the PTO output-rated torque/horsepower.
Side-Mounted PTO Locations
The first choice location for Side-Mounted PTOs is either of the PTO openings
on the main box.
The second choice, which is the compound PTO opening, is restricted to
those applications specifically requiring multi-speed PTOs with reverse
capability, such as some mechanical winches or unique speed or multiple
PTO requirements. However, a word of caution is in order when using these
locations. Operators should be trained to understand and follow the proper
operating procedures as described in the cab instructions, and avoid using the
neutralizing feature as a power disconnect for vehicle propulsion.
PTO Operating Procedures
Specific PTO operating procedures are described at the end of applicable
transmissions in the following section.
OPERATION 159
TRANSMISSION SHIFTING INSTRUCTIONS
CAUTION
The maximum safe operating oil temperature for MACK transmissions is
121°C (250°F) for mineral-based oil, and 148°C (300°F) for synthetic-based
oil. Continued operation with oil above this temperature will result in rapid
deterioration of the oil’s lubricating properties and is NOT recommended.
CAUTION
To avoid transmission damage, the vehicle must be completely stopped before being
shifted from REVERSE to any forward speed (and vice versa).
CAUTION
Never coast with the transmission in neutral. Never coast with the clutch depressed.
Shifting Instructions for Allison Automatic
Transmissions
Please refer to the applicable Allison automatic transmission operators manual
provided with your vehicle for complete shifting and operating instructions.
MACK T306G Shifting Instructions
The T306G is a six-speed overgear, non-synchronized transmission designed
for general highway use. Shifting is accomplished through a single shift lever
using the traditional H pattern.
Upshift — Start out in first gear and shift up to second, third, fourth, fifth and
sixth gears, double-clutching from one gear to the next.
Downshift — Downshift in reverse order (sixth through first), double-clutching
through each gear.
160 OPERATION
C0029341
T306G TRANSMISSION RATIOS
Gear
Ratio
1
7.50
2
4.08
3
2.41
4
1.50
5
1.00
6
0.71
Reverse
8.84
MACK TM308 Shifting Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is warmed before shifting the
transmission. To avoid transmission damage, do NOT change range while moving
in REVERSE. Use of the clutch brake is for shifting into first and reverse gears
only. Do not use the clutch brake to shift out of gear. Be careful not to overspeed
the engine during downshifting. Damage to powertrain components can result.
OPERATION 161
The TM308 is a non-synchronized transmission having a total of eight speeds
(6+2) with a non-synchronized air shifted compound section. This LO and HI
auxiliary compound section is controlled by an air-shift range selector valve
located on the shift lever. The LO range has two low gear ratios. In HI range
there are six forward gears which can be shifted in the normal manner, but
remember to double-clutch whether moving up or down through the gears.
For normal highway use, start in HI range, first gear and shift through second,
third, fourth, fifth and sixth. The ratio step between fifth and sixth is smaller
than all the other ratio steps. The two gears in LO range are designed for
off-highway use and in slow-moving operations (curb pouring, material
spreading, heavy load, steep grade).
Reverse — Reverse can be used in LO or HI range. To make a range shift
in reverse, bring the truck to a complete stop. Flip the range selector lever
to range desired.
162 OPERATION
C0029342
TM308 TRANSMISSION RATIOS
Ratios
Gear (Main Box)
LO Range
First Lo
17.77
Second Lo
10.94
Hi Range
First Hi
6.57
Second Hi
4.05
Third Hi
2.54
Fourth Hi
1.57
Fifth Hi
1.00
Sixth Hi
0.71
Reverse Lo
Reverse Hi
18.36
6.79
OPERATION 163
MACK TM308M Shifting Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is warmed before shifting the
transmission. Use of the clutch brake is for shifting into first and reverse gears
only. Do not use the clutch brake to shift out of gear. Be careful not to overspeed
the engine during downshifting. Damage to powertrain components can result.
The TM308M is a non-synchronized transmission having a total of eight
speeds (6+2) with a non-synchronized air shifted compound section. This LO
and HI auxiliary compound section is controlled by an air-shift range selector
valve located on the shift lever. The LO range has two low gear ratios. In HI
range there are six forward gears which can be shifted in the normal manner,
but remember to double-clutch whether moving up or down through the gears.
For normal highway use, start in HI range, first gear and shift through second,
third, fourth, fifth and sixth. The ratio step between fifth and sixth is smaller
than all the other ratio steps. The two gears in LO range are designed for
off-highway use and in slow-moving operations (curb pouring, material
spreading, heavy load, steep grade).
Reverse is used in LO range only. To avoid transmission damage when
shifting Forward to Reverse or Reverse to Forward:
• Bring vehicle to a stop.
• Move lever to NEUTRAL.
• Select low range.
• Select F or R as desired.
• Select lowest lever gear position.
• Release and depress clutch pedal.
• Select desired gear.
CAUTION
Vehicle operators must use extreme caution if operating a truck in the higher
reverse gears. Higher reverse gears will produce high reverse speeds which may be
difficult for drivers to control dependent on terrain or obstacles.
164 OPERATION
C0029343
TM308M TRANSMISSION RATIOS
Ratios
Direct Range
Reverse
Gear (Main Box)
LO Range
First Lo
17.77
15.59
Second Lo
10.94
9.60
Third Lo
6.02
Fourth Lo
3.73
Fifth Lo
2.37
Sixth Lo
1.69
First Hi
6.57
Second Hi
4.05
Third Hi
2.54
Fourth Hi
1.57
Fifth Hi
1.00
Sixth Hi
0.71
OPERATION 165
MACK TM309 Shifting Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is warmed before shifting the
transmission. To avoid transmission damage, do NOT change range while moving
in REVERSE. Use of the clutch brake is for shifting into first and reverse gears
only. Do not use the clutch brake to shift out of gear. Be careful not to overspeed
the engine during downshifting. Damage to powertrain components can result.
The TM309 is a non-synchronized transmission having a total of nine speeds
(6+3) with an air shifted non-synchronized compound section. This LO and
HI auxiliary compound section is controlled by an air-shift range selector
valve located on the shift lever. The LO range has three low gear ratios.
In HI range there are six forward gears which can be shifted in the normal
manner, but remember to double-clutch whether moving up or down through
the gears. For normal highway use, start in HI range, first gear and shift
through second, third, fourth, fifth and sixth. The ratio step between fifth and
sixth is smaller than all the other ratio steps. The three gears in LO range are
designed for off-highway use and in slow-moving operations (curb pouring,
material spreading, heavy load, steep grade). Only start in the lowest gear
necessary to move the vehicle. The extreme LO gear (1st low) is intended for
vehicular speed control and not for torque multiplication.For normal highway
use, start in HI range, first gear and shift through second, third, fourth, fifth
and sixth. The ratio step between fifth and sixth is smaller than all the other
ratio steps. The three gears in LO range are designed for off-highway use and
in slow-moving operations (curb pouring, material spreading, heavy load,
steep grade). Only start in the lowest gear necessary to move the vehicle.
The extreme LO gear (1st low) is intended for vehicular speed control and
not for torque multiplication.
Reverse — Reverse can be used in LO or HI range. To make a range shift
in reverse, bring the truck to a complete stop. Flip the range selector lever
to range desired (preselect). Move the shift lever out of reverse through
NEUTRAL and then back into reverse again. As the lever moves through
NEUTRAL, the range shift will be completed.
166 OPERATION
C0029344
TM309 TRANSMISSION RATIOS
Ratios
Gear (Main Box)
LO Range
First Lo
25.21
Second Lo
15.52
Third Lo
9.73
Hi Range
First Hi
6.57
Second Hi
4.05
Third Hi
2.54
Fourth Hi
1.57
Fifth Hi
1.00
Sixth Hi
0.71
Reverse Lo
Reverse Hi
25.67
6.79
OPERATION 167
MACK TM309M Shifting Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is warmed before shifting the
transmission. Use of the clutch brake is for shifting into first and reverse gears
only. Do not use the clutch brake to shift out of gear. Be careful not to overspeed
the engine during downshifting. Damage to powertrain components can result.
The TM309M is a non-synchronized transmission having a total of nine
speeds (6+3) with an air shifted non-synchronized compound section. This LO
and HI auxiliary compound section is controlled by an air-shift range selector
valve located on the shift lever. The LO range has three low gear ratios. In HI
range there are six forward gears which can be shifted in the normal manner,
but remember to double-clutch whether moving up or down through the gears.
For normal highway use, start in HI range, first gear and shift through second,
third, fourth, fifth and sixth. The ratio step between fifth and sixth is smaller
than all the other ratio steps. The three gears in LO range are designed
for off-highway use and in slow-moving operations (curb pouring, material
spreading, heavy load, steep grade). Only start in the lowest gear necessary
to move the vehicle. The extreme LO gear (1st low) is intended for vehicular
speed control and not for torque multiplication.
Reverse is used in LO range only. To avoid transmission damage when
shifting Forward to Reverse or Reverse to Forward:
• Bring vehicle to a stop.
• Move lever to NEUTRAL.
• Select low range.
• Select F or R as desired.
• Select lowest lever gear position.
• Release and depress clutch pedal.
• Select desired gear.
CAUTION
Vehicle operators must use extreme caution if operating a truck in the higher
reverse gears. Higher reverse gears will produce high reverse speeds which may be
difficult for drivers to control dependent on terrain or obstacles.
168 OPERATION
C0029345
TM309M TRANSMISSION RATIOS
Ratios
Direct Range
Reverse
Gear (Main Box)
LO Range
First Lo
25.21
22.12
Second Lo
15.52
13.62
Third Lo
9.73
8.54
Fourth Lo
5.30
Fifth Lo
3.37
Sixth Lo
2.40
First Hi
6.57
Second Hi
4.05
Third Hi
2.54
Fourth Hi
1.57
Fifth Hi
1.00
Sixth Hi
0.71
OPERATION 169
MACK T309, T309L and T309LR Shifting
Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is at operating temperature before
making range shifts. Always start in LO range. This also applies to dynamometer
testing. When the truck is stationary, do NOT shift into HI range and then start
moving the truck. Otherwise, damage to the synchronizer may result.
The T309 unit is a range-shifted transmission which has eight forward highway
speeds plus an extra LO speed gear in the LO range. This transmission
features a LO and HI auxiliary compound section controlled by an air-shift
range selector located on the shift lever. The compound section is equipped
with a synchronizer to facilitate LO-HI range shifting.
The LO range provides five low ratios. Never attempt to move the vehicle from
a stopped position in any gear higher than second gear. Depending on the
load, grade or road conditions, it may be necessary to start in LO speed gear
or first-second gears. Note that LO speed gear was designed for off-highway
use such as paving, material spreading or heavy load/steep grade conditions.
The HI range has four forward gears that can be shifted in the standard
manner. Remember, however, to double-clutch when moving up or down
through these gears.
REVERSE can be used in LO range only.
Upshift — Under normal highway conditions, with shift lever in NEUTRAL, flip
air-shift range selector to LO range, then shift the transmission into first gear
(see shift pattern). Shift through second, third and fourth, double-clutching
between gears. When maximum RPM is reached in fourth gear, flip air-shift
range selector to HI range (preselect) and then move shift lever through
NEUTRAL to fifth gear. As the shift lever passes through NEUTRAL, it will
put the transmission in HI range. Now continue double-clutching through
sixth, seventh and eighth gears.
CAUTION
Do NOT move the air-shift range selector while moving in REVERSE. Also, when
the truck is stationary, do NOT shift into HI range and then start moving the truck.
Damage to the synchronizer may result.
170 OPERATION
Downshift — To downshift the T309, shift from eighth to seventh, sixth and
fifth (HI range), double-clutching between gears. While still in fifth gear, flip the
air-shift range selector to LO range (preselect), then shift through NEUTRAL
to fourth gear. As you shift through NEUTRAL, the range shift to LO will be
completed. Move the shift lever to third, second and first, double-clutching
between gears.
T309 and T309L Reverse — Reverse can be used in LO range only.
T309LR Reverse — Reverse can be used in LO and HI range.
To make a range shift in reverse, bring the truck to a complete stop. Flip the
range selector to the range desired (preselect). Move the shift lever out of
reverse through NEUTRAL, and then back into reverse again. As the lever
moves through NEUTRAL, the range shift will be completed.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
C0029346
OPERATION 171
T309 TRANSMISSION RATIOS
Gear (Main Box)
LO Range
HI Range
LO
11.24
1/5
7.35
1.94
2/6
5.25
1.39
3/7
3.78
1.00
4/8
2.69
0.71
R
13.31
3.52
T309L TRANSMISSION RATIOS
Gear (Main Box)
LO Range
HI Range
LO
13.74
1/5
7.35
1.94
2/6
5.25
1.39
3/7
3.78
1.00
4/8
2.69
0.71
R
13.31
3.52
T309LR TRANSMISSION RATIOS
Gear (Main Box)
LO Range
HI Range
LO
13.74
1/5
7.35
1.94
2/6
5.25
1.39
3/7
3.78
1.00
4/8
2.69
0.71
R
24.24
6.41
Preferred Methods for Engaging T309 "Eighth" Gear (or any Hi-Range
Gear) for Output Shaft Driven Power Take-Off (PTO) Operation
Note: OPTIONAL RANGE ENGAGEMENT INDICATOR LAMP — If the vehicle
is so equipped, an indicator lamp, located in the cab, will illuminate to indicate that
the range shift has occurred.
172 OPERATION
Method #1 — PTO Operation with Wheels OFF the Ground
1. Position the vehicle for power take-off operation.
2. Stop the vehicle and apply the spring brakes.
3. Raise the vehicle wheels off the ground.
4. Shift the transmission to NEUTRAL.
5. Turn on PTO.
6. Place the range selector to HIGH.
7. Fully depress the clutch pedal and shift the transmission to REVERSE.
8. Slowly release the clutch pedal until the transmission range clutch
engagement is heard; or, if so equipped, until the range engagement indicator
lamp is lit.
9. Fully depress the clutch pedal.
10. Shift the transmission to EIGHTH gear.
11. Release the clutch pedal to begin PTO operation.
Method #2 — PTO Operation with Wheels ON the Ground
1. Position the vehicle for power take-off operation.
2. Stop the vehicle and apply the spring brakes.
3. Keep the vehicle wheels on the ground.
4. Shift the transmission to NEUTRAL.
5. Place the range selector to HIGH.
6. Fully depress the clutch pedal and shift the transmission to REVERSE.
7. Slowly release the clutch pedal until the transmission range clutch
engagement is heard; or, if so equipped, until the range engagement indicator
lamp is lit.
8. Fully depress the clutch pedal.
9. Turn on PTO.
10. Shift the transmission to EIGHTH gear.
11. Release the clutch pedal to begin PTO operation.
OPERATION 173
MACK T310 Shifting Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is warmed before making range
shifts. Always start in LO range. This also applies to dynamometer testing. When
the truck is stationary, do NOT shift into HI range and then start moving the truck.
Otherwise, damage to the synchronizer may result.
The T310 unit is a range-shifted transmission which has 10 forward "highway"
speeds. This transmission features a LO and HI auxiliary compound section
controlled by an air shift range selector located on the shift lever. The
compound section is equipped with a synchronizer to facilitate LO-/HI- range
shifting.
The LO range provides five low ratios. Never attempt to move the vehicle from
a stopped position in any gear higher than fourth speed gear. Depending on
load, grade, or road conditions, it may be necessary to start in first, second,
third or fourth speed gears. In HI range there are five forward gears that can
be shifted in the standard manner. Always remember, however, to double
clutch whether moving up or down through these gears. Reverse gear can be
used in LO range only.
Upshift - With the shift lever in NEUTRAL, flip the air shift range selector down
to LO range. Then shift the transmission into first gear. Shift up to second,
third, fourth and fifth speed gears, double clutching between the gears.
When maximum engine RPM has been reached in fifth gear, flip the air shift
range selector up to HI range (preselect). Then move the shift lever through
NEUTRAL to sixth gear. As the shift lever passes through NEUTRAL, the
transmission is placed into Hi range. Continue following the normal sequence
(7-8-9-10), being sure to double clutch from one gear to the next.
Downshift — Shift from 10th speed gear down through the HI range (9-8-7-6),
double clutching through each gear. While still in sixth speed gear, flip the
air shift range selector down to LO range (preselect). Then move the shift
lever through NEUTRAL to fifth speed gear. As the shift lever passes through
NEUTRAL, the transmission is placed into LO range. Then, shift down to
fourth, third, second and first speed gears, double clutching between all gears.
174 OPERATION
CAUTION
• Always start in LO range according to shift marker plate instructions. Never start
in a gear higher than fourth speed gear, even when dynamometer testing.
• When the truck is stationary, do not shift into HI range and then start moving the
truck. Damage to the synchronizer can result.
• Be careful not to overspeed the engine during downshifting. Damage to
powertrain components may result.
Reverse — Reverse can be used in LO only. To make a range shift in reverse,
bring the truck to a complete stop. Flip the range selector lever to range
desired (preselect). Move the shift lever out of reverse through NEUTRAL and
then back into reverse again. As the lever moves through NEUTRAL, the
range shift will be completed.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
OPERATION 175
C0029347
Ratios
Gear (Main Box)
LO
HI
1/6
13.81
2.67
2/7
10.05
1.94
3/8
7.18
1.39
4/9
5.17
1.00
5/10
3.75
0.73
R/R
14.73
2.85
176 OPERATION
MACK T310M, T310ME and T310MLR Shifting
Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is at operating temperature before
making range shifts. Always start in LO range. This also applies to dynamometer
testing. When the truck is stationary, do NOT shift into HI range and then start
moving the truck. Otherwise, damage to the synchronizer may result.
The T310M is a range-shifted transmission which has 10 forward speeds.
There is a LO and HI auxiliary compound section controlled by an air-shift
selector on the shifter. This compound section is equipped with a synchronizer
to facilitate LO-HI range shifting. The T310M transmission also provides a
multi-speed reverse feature by means of reverse gearing in the compound
case which works in conjunction with LO-LO, first and second speed gears
in the main box. The air-shift selector must be moved to the R (REVERSE)
position in order to utilize the multi-speed reverse feature.
LO range provides six low ratios for six forward gears in the T310M. HI range
provides four additional forward gears which can be shifted in the standard
manner. Remember, however, to double-clutch when moving up or down
through the gears. For normal highway use, start in LO range, first gear
and shift through second, third and fourth. The LO-LO and LO positions
in LO range for this transmission are designed for use in off-highway and
slow-moving operations such as curb pouring, material spreading, heavy
load/steep grade. REVERSE is used in LO range for four reverse speeds.
Upshift — Begin in first gear (shown as 1/5 on shift pattern diagram) with
air-shift selector in LO range. Upshift to second gear (2/6 on shift pattern
diagram) LO range in the normal manner (double-clutching). When ready to
upshift again, depress the clutch pedal and release the accelerator pedal in
the normal manner. Repeat this shifting pattern through the remaining gears
up to fourth speed (4/8 on shift pattern diagram). When maximum engine
RPM has been reached in fourth gear, flip the air-shift selector to HI range
(preselect), then double-clutch and shift to fifth gear. As the shift lever passes
through NEUTRAL, it will put the transmission in HI range. Continue to upshift
through normal sixth, seventh and eighth gears, while double-clutching.
OPERATION 177
Downshift — Downshift as normal from eighth to seventh, sixth and fifth
in HI range (double-clutching between all gears). The next lower shift will
be to fourth gear LO range. While still in fifth gear, flip the air-shift selector
to LO range (preselect), then double-clutch and move the shift lever through
NEUTRAL to fourth gear. The move through NEUTRAL activates the air-shift
mechanism, this time to LO range. The next lower gear is third gear LO
range. Double-clutch down through the remaining gears to first gear LO range
as needed.
CAUTION
When the truck is stationary, do NOT shift into HI range and then start moving the
truck. Damage to the synchronizer may result.
Reverse is used in LO range only. To avoid transmission damage when
shifting Forward to Reverse or Reverse to Forward:
• Bring vehicle to a stop.
• Move lever to NEUTRAL.
• Select low range.
• Select F or R as desired.
• Select lowest lever gear position.
• Release and depress clutch pedal.
• Select desired gear.
178 OPERATION
C0029348
T310M AND T310ME TRANSMISSION RATIOS
Gear (Main Box)
LO Range
HI Range
Reverse
LOLO
17.35
15.22
LO
11.40
10.00
1/5
7.45
1.94
6.54
2/6
5.33
1.39
4.67
3/7
3.83
1.00
3.37
4/8
2.78
0.73
2.44
OPERATION 179
T310MLR TRANSMISSION RATIOS
Gear (Main Box)
LO Range
HI Range
Reverse
LOLO
27.30
23.96
LO
13.90
12.22
1/5
7.45
1.94
6.54
2/6
5.33
1.39
4.67
3/7
3.83
1.00
3.37
4/8
2.73
0.71
2.40
Preferred Method for Engaging T310M or T310MLR High Range Gear for
Output Shaft Driven Power Take-Off Operation
After positioning the vehicle for power take-off operation:
1. Shift the transmission to NEUTRAL.
2. Engage power take-off drive.
3. Move range selector to HI range.
4. Disengage engine clutch.
5. Select "tenth" gear (8 on the shift marker plate) for T310M or T310MLR.
6. Engage clutch when power take-off operation is desired.
CAUTION
When the truck is stationary, do NOT shift into HI range and then start moving the
truck. Damage to the synchronizer may result.
180 OPERATION
MACK T313-T313L-T313LR Shifting Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is at operating temperature before
making range shifts. Always start in LO range. This also applies to dynamometer
testing. When the truck is stationary, do NOT shift into HI range and then start
moving the truck. Otherwise, damage to the synchronizer may result.
The T313(L)(LR) is a range-shifted transmission with 12 forward highway
speeds and an extra LO gear in the LO range. LO and HI ranges are
controlled by an air-shift range selector.
Note: When making a SPLIT SHIFT from gear to gear, the splitter switch must not
be actuated, either up or down, until the main box is in NEUTRAL. When making
a SPLIT SHIFT in the same gear to a preselected gear, especially under a heavy
load, the splitter will not shift until the driveline torque is relieved. This can be done
by depressing the clutch pedal and releasing it, or by backing off the throttle and
reapplying it. The splitter switch must not be actuated, either up or down, until
IMMEDIATELY before the driveline torque is relieved. When making a RANGE
SHIFT, it is important to preselect the range shift. This means that the range selector
must be moved to its next position (up or down) BEFORE the gearshift lever is
moved. Then move the gearshift lever through NEUTRAL to the next desired gear
position. As the lever passes through NEUTRAL, the range shift will be completed.
CAUTION
Do not "play" with the splitter and range selector tabs at a stop light, flipping from
high to low range or HI-LO split. These controls are not intended for entertainment.
Such activity can adversely impact the life of the transmission.
Upshift — For purposes of explaining the shifting procedures through ALL
gears, assume that the vehicle has a full load and will climb a slight grade.
Before moving the vehicle, the range selector must be in LO range and the
splitter switch in LO-split. With the shift lever in NEUTRAL, move the splitter to
LO-split (if needed), then the range to LO range (if needed).
OPERATION 181
Refer to the shift pattern and move the shift lever to LO speed gear (LO
range, LO-split). Apply accelerator, engage the clutch, and accelerate to
governed speed. Shift up through first, second, third and fourth speed gears,
double-clutching between the gears.
To continue while in fourth gear (LO-split), flip the range selector up to HI range
(preselect), then move the shift lever through NEUTRAL to fifth gear. As the
lever moves through NEUTRAL, the range shift to HI will be completed. You
are now in fifth gear LO-split (HI range). Use a combination of the splitter and
shift lever to continue shifting to fifth HI-split, sixth LO-split, sixth HI-split and so
on, until you reach eighth HI-split. Remember to double-clutch between gears.
To upshift from LO-split to HI-split (in the same gear), accelerate the engine
to governed speed, move the splitter switch to HI (preselect), depress the
clutch and back off the accelerator pedal. Reapply the accelerator and engage
the clutch when the audible shift is heard, or when the engine speed falls by
approximately 200 rpm. Depressing the clutch may not be necessary to break
the driveline torque, but this will vary with road and load conditions.
To upshift from a HI-split gear to the next higher gears LO-split (in HI range),
accelerate the engine to governed speed, then move the splitter switch to LO
as you move the shift lever through NEUTRAL to the next higher gear. Note
that the splitter switch must not be actuated down to the LO position until
the main box is in NEUTRAL.
Downshift — Shift from eighth HI-split to eighth LO-split, then seventh
HI-split, seventh LO-split and so on (double-clutching between the gears),
until you reach fifth LO-split.
While in fifth gear LO-split, flip the range selector down to LO range (preselect),
then move the shift lever through NEUTRAL to fourth gear (double-clutch and
use the throttle in the normal manner between gears). As the shift lever moves
through NEUTRAL, the range shift to LO will be completed. You are now in
fourth gear LO-split (LO range). Continue downshifting, using the shift lever in
the normal manner until you reach LO speed gear (LO range, LO-split).
To downshift from HI-split to LO-split (in the same gear) as engine speed falls,
move the splitter to LO (preselect), then release and reapply the accelerator
pedal. An audible shift completion should be heard.
To downshift from a LO-split gear to the next lower gears HI-split (in HI range)
as engine speed falls, move the splitter switch to HI as you move the shift
lever through NEUTRAL to the next lower gear. Note that the splitter switch
must not be actuated up to the HI position until the main box is in NEUTRAL.
Remember to double-clutch between gears.
T313 and T313L Reverse — Reverse can be used in LO range only.
T313LR Reverse — Reverse can be used in LO and HI range.
To make a range shift in reverse, bring the truck to a complete stop. Flip the
range selector to the range desired (preselect). Move the shift lever out of
reverse through NEUTRAL, and then back into reverse again. As the lever
moves through NEUTRAL, the range shift will be completed.
182 OPERATION
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
C0029349
OPERATION 183
T313, T313L AND T313LR TRANSMISSION RATIOS
Ratios
Gear
(Main
Box)
Splitter
Range
T313LR
T313
T313L
LO
LO
LO
16.42
13.44
16.42
1
LO
LO
8.78
8.78
8.78
2
LO
LO
6.28
6.28
6.28
3
LO
LO
4.52
4.52
4.52
4
LO
LO
3.22
3.22
3.22
Range Shift Here
5
LO
HI
2.29
2.29
2.29
5
HI
HI
1.94
1.94
1.94
6
LO
HI
1.64
1.64
1.64
6
HI
HI
1.39
1.39
1.39
7
LO
HI
1.18
1.18
1.18
7
HI
HI
1.00
1.00
1.00
8
LO
HI
0.84
0.84
0.84
8
HI
HI
0.71
0.71
0.71
R
LO
LO
28.98
15.91
15.91
R
HI
HI
6.41
3.52
3.52
184 OPERATION
Rear Case, Side-Mounted PTO Operating Procedures (T313, T313L and
T313LR)
When engaging the PTO —
1. Select LO-split using the splitter switch and select LO range using the
range selector.
Note: The transmission MUST be in LO range and LO-split at all times during PTO
operation.
2. Depress the clutch pedal to disengage the clutch.
3. Set the parking brakes.
4. Move the main box shift lever to the NEUTRAL position.
5. Move the dash-mounted compound NEUTRAL control valve to the ON
position, which moves the synchro clutch to a NEUTRAL position.
6. Engage the PTO.
7. Move the main box shift lever to the desired ratio.
8. Release the clutch pedal to engage the clutch.
9. Operate the PTO-driven load.
When disengaging the PTO —
1. Depress the clutch pedal to disengage the clutch.
2. Move the main box shift lever to NEUTRAL.
3. Disengage the PTO.
4. Move the dash-mounted compound NEUTRAL control valve to the OFF
position, which moves the synchro clutch back to LO range.
5. Move the shift lever to the desired main gear box ratio.
6. Release the parking brakes.
7. Release the clutch pedal to engage the clutch.
OPERATION 185
MACK T31321, T313L21 and T313LR21 Shifting
Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is at operating temperature before
making range shifts. Always start in LO range. This also applies to dynamometer
testing. When the truck is stationary, do NOT shift into HI range and then start
moving the truck. Otherwise, damage to the synchronizer may result.
The T313(L)(LR)21 is a range-shifted transmission with 12 forward highway
speeds and an extra LO gear in the LO range. LO and HI ranges are
controlled by an air-shift range selector.
Note: When making a SPLIT SHIFT from gear to gear, the splitter switch must not
be actuated, either up or down, until the main box is in NEUTRAL. When making
a SPLIT SHIFT in the same gear to a preselected gear, especially under a heavy
load, the splitter will not shift until the driveline torque is relieved. This can be done
by depressing the clutch pedal and releasing it, or by backing off the throttle and
reapplying it. The splitter switch must not be actuated, either up or down, until
IMMEDIATELY before the driveline torque is relieved. When making a RANGE
SHIFT, it is important to preselect the range shift. This means that the range selector
must be moved to its next position (up or down) BEFORE the gearshift lever is
moved. Then move the gearshift lever through NEUTRAL to the next desired gear
position. As the lever passes through NEUTRAL, the range shift will be completed.
Upshift — For purposes of explaining the shifting procedures through ALL
gears, assume that the vehicle has a full load and will climb a slight grade.
Before moving the vehicle, the range selector must be in LO range and the
splitter switch in LO-split. With the shift lever in NEUTRAL, move the splitter to
LO-split (if needed), then the range to LO range (if needed).
Refer to the shift pattern and move the shift lever to LO speed gear (LO
range, LO-split). Apply accelerator, engage the clutch, and accelerate to
governed speed. Shift up through first, second, third-fourth speed gears,
double-clutching between the gears.
To continue while in fourth gear (LO-split), flip the range selector up to HI range
(preselect), then move the shift lever through NEUTRAL to fifth gear. As the
lever moves through NEUTRAL, the range shift to HI will be completed. You
are now in fifth gear LO-split (HI range). Use a combination of the splitter and
shift lever to continue shifting to fifth HI-split, sixth LO-split, sixth HI-split and so
on, until you reach eighth HI-split. Remember to double-clutch between gears.
186 OPERATION
To upshift from LO-split to HI-split (in the same gear), accelerate the engine
to governed speed, move the splitter switch to HI (preselect), depress the
clutch and back off the accelerator pedal. Reapply the accelerator and engage
the clutch when the audible shift is heard, or when the engine speed falls by
approximately 200 rpm. Depressing the clutch may not be necessary to break
the driveline torque, but this will vary with road and load conditions.
To upshift from a HI-split gear to the next higher gear’s LO-split (in HI range),
accelerate the engine to governed speed, then move the splitter switch to LO
as you move the shift lever through NEUTRAL to the next higher gear. Note
that the splitter switch must not be actuated down to the LO position until
the main box is in NEUTRAL.
Downshift — Shift from eighth HI-split to eighth LO-split, then seventh
HI-split, seventh LO-split and so on (double-clutching between the gears),
until you reach fifth LO-split.
While in fifth gear LO-split, flip the range selector down to LO range (preselect),
then move the shift lever through NEUTRAL to fourth gear (double-clutch and
use the throttle in the normal manner between gears). As the shift lever moves
through NEUTRAL, the range shift to LO will be completed. You are now in
fourth gear LO-split (LO range). Continue downshifting, using the shift lever in
the normal manner until you reach LO speed gear (LO range, LO-split).
To downshift from HI-split to LO-split (in the same gear) as engine speed falls,
move the splitter to LO (preselect), then release and reapply the accelerator
pedal. An audible shift completion should be heard.
To downshift from a LO-split gear to the next lower gears HI-split (in HI range)
as engine speed falls, move the splitter switch to HI as you move the shift
lever through NEUTRAL to the next lower gear. Note that the splitter switch
must not be actuated up to the HI position until the main box is in NEUTRAL.
Remember to double-clutch between gears.
T31321 and T313L21 Reverse — Reverse can be used in LO range only.
T313LR21 Reverse — Reverse can be used in LO and HI range.
To make a range shift in reverse, bring the truck to a complete stop. Flip the
range selector to the range desired (preselect). Move the shift lever out of
reverse through NEUTRAL, and then back into reverse again. As the lever
moves through NEUTRAL, the range shift will be completed.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
OPERATION 187
C0029350
188 OPERATION
T31321, T313L21 AND T313LR21 TRANSMISSION RATIOS
Ratios
Gear
(Main
Box)
Splitter
Range
T31321
T313LR21
T313L21
LO
LO
LO
13.44
16.42
16.42
1
LO
LO
8.78
8.78
8.78
2
LO
LO
6.28
6.28
6.28
3
LO
LO
4.52
4.52
4.52
4
LO
LO
3.22
3.22
3.22
Range Shift Here
5
LO
HI
2.29
2.29
2.29
5
HI
HI
1.94
1.94
1.94
6
LO
HI
1.64
1.64
1.64
6
HI
HI
1.39
1.39
1.39
7
LO
HI
1.18
1.18
1.18
7
HI
HI
1.00
1.00
1.00
8
LO
HI
0.84
0.84
0.84
8
HI
HI
0.71
0.71
0.71
R
LO
LO
15.91
28.98
15.91
R
HI
HI
3.52
6.41
3.52
OPERATION 189
MACK T318, T318L and T318LR Shifting
Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is at operating temperature before
making range shifts. Always start in LO range. This also applies to dynamometer
testing. When the truck is stationary, do NOT shift into HI range and then start
moving the truck. Otherwise, damage to the synchronizer may result.
Note: When making a SPLIT SHIFT from gear to gear, the splitter switch must not
be actuated, either up or down, until the main box is in NEUTRAL. When making
a SPLIT SHIFT in the same gear to a preselected gear, especially under a heavy
load, the splitter will not shift until the driveline torque is relieved. This can be done
by depressing the clutch pedal and releasing it, or by backing off the throttle and
reapplying it. The splitter switch must not be actuated, either up or down, until
IMMEDIATELY before the driveline torque is relieved. When making a RANGE
SHIFT, it is important to preselect the range shift. This means that the range selector
must be moved to its next position (up or down) BEFORE the gearshift lever is
moved. Then move the gearshift lever through NEUTRAL to the next desired gear
position. As the lever passes through NEUTRAL, the range shift will be completed.
Upshift — For purposes of explaining the shifting procedures through ALL
gears, assume that the vehicle has a full load and will climb a slight grade.
To prepare for moving the vehicle, position the shift lever in NEUTRAL, select
LO-split using the splitter switch, and select LO range using the range selector.
Refer to the shift pattern and move the shift lever to LO speed gear (LO
range, LO-split). Apply accelerator and engage the clutch, then accelerate
to governed speed. Select HI on the splitter switch (preselect) and release
the accelerator pedal long enough for the split shift to complete. Reapply the
accelerator. Shift through first LO-split, first HI-split, second LO-split, second
HI-split and so on, until you reach fourth HI-split. Remember to double-clutch
between gears.
To continue while in fourth gear HI-split, flip the range selector up to HI range
(preselect), and as you move the shift lever through NEUTRAL to fifth gear,
move the splitter switch from HI to LO. As the lever moves through NEUTRAL,
the range shift to HI will be completed. You are now in fifth gear LO-split (HI
range). Continue shifting to fifth HI-split, sixth LO-split, sixth HI-split and so
on, until you reach eighth HI-split. Remember to double-clutch between gears.
190 OPERATION
To upshift from LO-split to HI-split (in the same gear), accelerate the engine
to governed speed, move the splitter switch to HI (preselect), depress the
clutch and back off the accelerator pedal. Reapply the accelerator and engage
the clutch when the audible shift is heard, or when the engine speed falls by
approximately 200 rpm. Depressing the clutch may not be necessary to break
the driveline torque, but this will vary with road and load conditions.
To upshift from a HI-split gear to the next higher gears LO-split (in the same
range), accelerate the engine to governed speed, then move the splitter switch
to LO as you move the shift lever through NEUTRAL to the next higher gear.
Note that the splitter switch must not be actuated down to the LO position
until the main box is in NEUTRAL.
Downshift — Shift from eighth HI-split to eighth LO-split, then seventh
HI-split, seventh LO-split and so on (double-clutching between the gears),
until you reach fifth LO-split.
To continue while in fifth gear LO-split, flip the range selector down to LO range
(preselect), and as you move the gearshift lever through NEUTRAL to fourth
gear, move the splitter switch from LO to HI. As the shift lever moves through
NEUTRAL, the range shift to LO will be completed. You are now in fourth gear
HI-split (LO range). Continue downshifting, using the shift lever and splitter in
the normal manner, until you reach LO speed gear (LO range, LO-split).
To downshift from HI-split to LO-split (in the same gear) as engine speed falls,
move the splitter to LO (preselect), then release and reapply the accelerator
pedal. An audible shift completion should be heard.
To downshift from a LO-split gear to the next lower gear’s HI-split (in the same
range) as engine speed falls, move the splitter switch to HI as you move the
shift lever through NEUTRAL to the next lower gear. Note that the splitter
switch must not be actuated up to the HI position until the main box is in
NEUTRAL. Remember to double-clutch between gears using the accelerator
pedal to synchronize the transmission components.
T318 and T318L Reverse — Reverse can be used in LO range only.
T318LR Reverse — Reverse can be used in LO and HI range.
To make a range shift in reverse, bring the truck to a complete stop. Flip the
range selector to the range desired (preselect). Move the shift lever out of
reverse through NEUTRAL, and then back into reverse again. As the lever
moves through NEUTRAL, the range shift will be completed.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
OPERATION 191
C0029351
192 OPERATION
T318, T318L AND T318LR TRANSMISSION RATIOS
Ratios
Gear
(Main
Box)
Splitter
Range
T318
T318LR
T318L
LO
LO
LO
13.44
16.42
16.42
LO
HI
LO
11.40
13.93
13.93
1
LO
LO
8.78
8.78
8.78
1
HI
LO
7.45
7.45
7.45
2
LO
LO
6.28
6.28
6.28
2
HI
LO
5.33
5.33
5.33
3
LO
LO
4.52
4.52
4.52
3
HI
LO
3.83
3.83
3.83
4
LO
LO
3.22
3.22
3.22
4
HI
LO
2.73
2.73
2.73
Range Shift Here
5
LO
HI
2.29
2.29
2.29
5
HI
HI
1.94
1.94
1.94
6
LO
HI
1.64
1.64
1.64
6
HI
HI
1.39
1.39
1.39
7
LO
HI
1.18
1.18
1.18
7
HI
HI
1.00
1.00
1.00
8
LO
HI
0.84
0.84
0.84
8
HI
HI
0.71
0.71
0.71
R
LO
LO
15.91
28.98
15.91
R
LO
HI
13.49
24.58
13.49
R
HI
HI
3.52
6.41
3.52
OPERATION 193
Rear Case, Side-Mounted PTO Operating Procedures (T318, T318L and
T318LR)
When engaging the PTO —
1. Select LO-split using the splitter switch and select LO range using the
range selector.
Note: The transmission MUST be in LO range and LO-split at all times during PTO
operation.
2. Depress the clutch pedal to disengage the clutch.
3. Set the parking brakes.
4. Move the main box shift lever to the NEUTRAL position.
5. Move the dash-mounted compound NEUTRAL control valve to the ON
position, which moves the synchro clutch to a NEUTRAL position.
6. Engage the PTO.
7. Move the main box shift lever to the desired ratio.
8. Release the clutch pedal to engage the clutch.
9. Operate the PTO-driven load.
When disengaging the PTO —
1. Depress the clutch pedal to disengage the clutch.
2. Move the main box shift lever to NEUTRAL.
3. Disengage the PTO.
4. Move the dash-mounted compound NEUTRAL control valve to the OFF
position, which moves the synchro clutch back to LO range.
5. Move the shift lever to the desired main gear box ratio.
6. Release the parking brakes.
7. Release the clutch pedal to engage the clutch.
194 OPERATION
Preferred Methods for Engaging T318(L)(LR) "Eighteenth" Gear (or any
HI-range gear) for Output Shaft Driven Power Take-Off Operation
Method #1
After positioning the vehicle for power take-off operation, and with vehicle
wheels off the ground:
1. Shift the transmission to NEUTRAL.
2. Engage power take-off drive.
3. Move the range selector to HI range.
4. Disengage the engine clutch and select REVERSE.
5. Feather the clutch until the transmission range clutch engagement is heard.
6. Disengage the engine clutch.
7. Select 18th speed gear for T318LR.
8. Engage the clutch when power take-off operation is desired.
Method #2
After positioning the vehicle for power take-off operation, and with vehicle
wheels on the ground:
1. Shift the transmission to NEUTRAL.
2. Move the range selector to HI range.
3. Disengage the engine clutch and select REVERSE.
4. Feather the clutch until the transmission range clutch engagement is heard.
5. Disengage the engine clutch.
6. Engage power take-off drive.
7. Select 18th speed gear for T318LR.
8. Engage the clutch when power take-off operation is desired.
OPERATION 195
MACK T31821, T318L21 and T318LR21 Shifting
Instructions
CAUTION
Make sure air pressure is at least 90 psi and unit is at operating temperature before
making range shifts. Always start in LO range. This also applies to dynamometer
testing. When the truck is stationary, do NOT shift into HI range and then start
moving the truck. Otherwise, damage to the synchronizer may result.
Note: When making a SPLIT SHIFT from gear to gear, the splitter switch must not
be actuated, either up or down, until the main box is in NEUTRAL. When making
a SPLIT SHIFT in the same gear to a preselected gear, especially under a heavy
load, the splitter will not shift until the driveline torque is relieved. This can be done
by depressing the clutch pedal and releasing it, or by backing off the throttle and
reapplying it. The splitter switch must not be actuated, either up or down, until
IMMEDIATELY before the driveline torque is relieved. When making a RANGE
SHIFT, it is important to preselect the range shift. This means that the range selector
must be moved to its next position (up or down) BEFORE the gearshift lever is
moved. Then move the gearshift lever through NEUTRAL to the next desired gear
position. As the lever passes through NEUTRAL, the range shift will be completed.
Upshift — For purposes of explaining the shifting procedures through ALL
gears, assume that the vehicle has a full load and will climb a slight grade.
To prepare for moving the vehicle, position the shift lever in NEUTRAL, select
LO-split using the splitter switch, and select LO range using the range selector.
Refer to the shift pattern and move the shift lever to LO speed gear (LO
range, LO-split). Apply accelerator and engage the clutch, then accelerate
to governed speed. Select HI on the splitter switch (preselect) and release
the accelerator pedal long enough for the split shift to complete. Reapply the
accelerator. Shift through first LO-split, first HI-split, second LO-split, second
HI-split and so on, until you reach fourth HI-split. Remember to double-clutch
between gears.
To continue while in fourth gear HI-split, flip the range selector up to HI range
(preselect), and as you move the shift lever through NEUTRAL to fifth gear,
move the splitter switch from HI to LO. As the lever moves through NEUTRAL,
the range shift to HI will be completed. You are now in fifth gear LO-split (HI
range). Continue shifting to fifth HI-split, sixth LO-split, sixth HI-split and so
on, until you reach eighth HI-split. Remember to double-clutch between gears.
196 OPERATION
To upshift from LO-split to HI-split (in the same gear), accelerate the engine
to governed speed, move the splitter switch to HI (preselect), depress the
clutch and back off the accelerator pedal. Reapply the accelerator and engage
the clutch when the audible shift is heard, or when the engine speed falls by
approximately 200 rpm. Depressing the clutch may not be necessary to break
the driveline torque, but this will vary with road and load conditions.
To upshift from a HI-split gear to the next higher gear’s LO-split (in the same
range), accelerate the engine to governed speed, then move the splitter switch
to LO as you move the shift lever through NEUTRAL to the next higher gear.
Note that the splitter switch must not be actuated down to the LO position
until the main box is in NEUTRAL.
Downshift — Shift from eighth HI-split to eighth LO-split, then seventh
HI-split, seventh LO-split and so on (double-clutching between the gears),
until you reach fifth LO-split.
To continue while in fifth gear LO-split, flip the range selector down to LO range
(preselect), and as you move the gearshift lever through NEUTRAL to fourth
gear, move the splitter switch from LO to HI. As the shift lever moves through
NEUTRAL, the range shift to LO will be completed. You are now in fourth gear
HI-split (LO range). Continue downshifting, using the shift lever and splitter in
the normal manner, until you reach LO speed gear (LO range, LO-split).
To downshift from HI-split to LO-split (in the same gear) as engine speed falls,
move the splitter to LO (preselect), then release and reapply the accelerator
pedal. An audible shift completion should be heard.
To downshift from a LO-split gear to the next lower gear’s HI-split (in the same
range) as engine speed falls, move the splitter switch to HI as you move the
shift lever through NEUTRAL to the next lower gear. Note that the splitter
switch must not be actuated up to the HI position until the main box is in
NEUTRAL. Remember to double-clutch between gears using the accelerator
pedal to synchronize the transmission components.
T31821 and T318L21 Reverse — Reverse can be used in LO range only.
T318LR21 Reverse — Reverse can be used in LO and HI range.
To make a range shift in reverse, bring the truck to a complete stop. Flip the
range selector to the range desired (preselect). Move the shift lever out of
reverse through NEUTRAL, and then back into reverse again. As the lever
moves through NEUTRAL, the range shift will be completed.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
OPERATION 197
C0029352
198 OPERATION
T31821, T318L21 AND T318LR21 TRANSMISSION RATIOS
Ratios
Gear
(Main
Box)
Splitter
Range
T31821
T318LR21
T318L21
LO
LO
LO
13.44
16.42
16.42
LO
HI
LO
11.40
13.93
13.93
1
LO
LO
8.78
8.78
8.78
1
HI
LO
7.45
7.45
7.45
2
LO
LO
6.28
6.28
6.28
2
HI
LO
5.33
5.33
5.33
3
LO
LO
4.52
4.52
4.52
3
HI
LO
3.83
3.83
3.83
4
LO
LO
3.22
3.22
3.22
4
HI
LO
2.73
2.73
2.73
Range Shift Here
5
LO
HI
2.29
2.29
2.29
5
HI
HI
1.94
1.94
1.94
6
LO
HI
1.64
1.64
1.64
6
HI
HI
1.39
1.39
1.39
7
LO
HI
1.18
1.18
1.18
7
HI
HI
1.00
1.00
1.00
8
LO
HI
0.84
0.84
0.84
8
HI
HI
0.71
0.71
0.71
R
LO
LO
15.91
28.98
15.91
R
LO
HI
13.49
24.58
13.49
R
HI
HI
3.52
6.41
3.52
OPERATION 199
Rear Case, Side-Mounted PTO Operating Procedures (T31821, T318L21
and T318LR21)
When engaging the PTO —
1. Select LO-split using the splitter switch and select LO range using the
range selector.
Note: The transmission MUST be in LO range and LO-split at all times during PTO
operation.
2. Depress the clutch pedal to disengage the clutch.
3. Set the parking brakes.
4. Move the main box shift lever to the NEUTRAL position.
5. Move the dash-mounted compound NEUTRAL control valve to the ON
position, which moves the synchro clutch to a NEUTRAL position.
6. Engage the PTO.
7. Move the main box shift lever to the desired ratio.
8. Release the clutch pedal to engage the clutch.
9. Operate the PTO-driven load.
When disengaging the PTO —
1. Depress the clutch pedal to disengage the clutch.
2. Move the main box shift lever to NEUTRAL.
3. Disengage the PTO.
4. Move the dash-mounted compound NEUTRAL control valve to the OFF
position, which moves the synchro clutch back to LO range.
5. Move the shift lever to the desired main gear box ratio.
6. Release the parking brakes.
7. Release the clutch pedal to engage the clutch.
200 OPERATION
Preferred Methods for Engaging T318(L)(LR)21 "Eighteenth" Gear (or any
HI-range gear) for Output Shaft Driven Power Take-Off (PTO) Operation
Method #1
After positioning the vehicle for power take-off operation, and with vehicle
wheels off the ground:
1. Shift the transmission to NEUTRAL.
2. Engage power take-off drive.
3. Move the range selector to HI range.
4. Disengage the engine clutch and select REVERSE.
5. Feather the clutch until the transmission range clutch engagement is heard.
6. Disengage the engine clutch.
7. Select 18th speed gear for T318L(R)21.
8. Engage the clutch when power take-off operation is desired.
Method #2
After positioning the vehicle for power take-off operation, and with vehicle
wheels on the ground:
1. Shift the transmission to NEUTRAL.
2. Move the range selector to HI range.
3. Disengage the engine clutch and select REVERSE.
4. Feather the clutch until the transmission range clutch engagement is heard.
5. Disengage the engine clutch.
6. Engage power take-off drive.
7. Select 18th speed gear for T318L(R)21.
8. Engage the clutch when power take-off operation is desired.
OPERATION 201
AXLES
Rear Axles Other Than MACK
Please refer to the operators manual provided with your vehicle for axles
other than MACK.
MACK Rear Axles
Mack Trucks, Inc. provides axle housings in three capacity classifications:
• Medium Duty
• Heavy Duty
• Extra-Heavy Duty
To deliver the appropriate amount of torque to the driving wheels, MACK
offers dual-reduction carriers in a variety of ratios.
Mack Trucks, Inc. offers a large variety of four-wheel-drive tandem axles with
top-mounted, dual-reduction carriers (for straight line through drive). Carriers
are also available in a large number of ratios.
All four-wheel-drive tandem carriers are available with the MACK inter-axle
power divider third differential (with or without a power divider lockout).
MACK rear axles are designed so the entire load is carried by the axle housing
(through the wheel bearings mounted on the housing spindle). The rear axle
shafts are either free-splined (both ends) or integral flange type. Both types of
axle shafts can be removed without removing or disturbing the rear wheels.
To avoid excessive tire wear, proper maintenance must be practiced and rear
axle tires must be matched.
CAUTION
The maximum safe operating oil temperature for a MACK rear axle is 121°C
(250°F) for mineral-based oil, and 148°C (300°F) for synthetic-based oil.
Continued operation with oil above this temperature will result in rapid
deterioration of the oil’s lubricating properties and is NOT recommended.
202 OPERATION
Inter-Axle Power Divider Lockout (If Equipped)
The MACK power divider can be rendered inoperative, during short periods of
poor traction, using a power divider lockout. When the power divider lockout
is engaged, both axles are locked together (in positive through-drive) for
maximum traction with no differential action between axles. It is not necessary
to stop the vehicle to engage the power divider lockout. The lockout may
be engaged while the vehicle is moving at less than 30 mph, as long as the
wheels are not spinning.
CAUTION
Do not engage the power divider lockout if the wheels are spinning.
Note: Even when no traction is available at the spinning wheel, the driver can
"feather" the brakes (apply the brakes slightly), creating enough resistance at that
wheel to allow power to the axle with traction. Feathering brakes should not be done
with power divider lockout engaged.
Note: For vendor axles, see the vendor manual furnished with the vehicle.
Engaging the Power Divider Lockout
Normally, the Power Divider switch is in the OUT (disengaged) position. In
poor traction conditions, it may be necessary to provide positive through-drive
to both axles by flipping the switch to the locked (engaged) position.
1. Push switch to engage.
2. Momentarily release the accelerator pedal to allow the shift to take place,
then drive through the slippery area.
Note: A lockout indicator lamp will remain lit as long as the lockout is engaged. This
is to remind the driver to release the lockout as soon as normal traction is regained.
3. When driving conditions permit, unlock the power divider by moving the
Power Divider switch back to the OUT (disengaged) position. Then release
the accelerator pedal momentarily (to shift out of the locked position) and
drive as usual.
CAUTION
OPERATION 203
Do NOT (under any circumstances) engage or disengage the lockout while the
drive wheels are actually slipping or spinning; clashing between the lockout sliding
clutch and the outer cam may result.
204 Mack, US10 Emissions Solution
DIESEL PARTICULATE FILTERS
Your new MACK chassis is equipped with a 2010 emission compliant
engine and an exhaust aftertreatment system which includes a Diesel
Particulate Filter (DPF), which reduces soot and particulate emissions into the
atmosphere. Vehicles equipped with a Diesel Particulate Filter require the
use of EO-O Premium Plus (or VDS-4) specification high performance diesel
engine oil and Ultra Low Sulfur Diesel (ULSD) fuel.
CAUTION
Use of diesel fuel other than ULSD and engine oils other than EO-O Premium
Plus (or VDS-4), will adversely affect performance, efficiency and durability of
the DPF system and the engine, to the point where the engine may not run at all.
Manufacturer’s warranties will also be rendered void due to usage of improper fuel.
Unapproved fuel additives (including engine oil) are NOT permitted.
Mack Trucks, Inc. offers two different types of DPF systems:
• Conventional DPF (passive regeneration and parked regeneration)
Thermal Regeneration Unit (TRU) DPF (moving regeneration and parked
regeneration)
Mack, US10 Emissions Solution 205
As well as two different mounting styles:
1. MACK Vertical Back-of-Cab DPF both on conventional DPF or conventional
DPF or TRU
2. Mack-Cap DPF, which is a space saying unit that is mounted inside the
frame (conventional only)
C0029353
A Diesel Particulate Filter (DPF) takes the place of the standard muffler. The
DPF is used to meet EPA requirements to help reduce soot and particulate
emissions into the atmosphere. The particulates are removed by collecting in
the DPF unit, where they are eventually oxidized with passive regeneration
or active regeneration of the filter. The electrical system and exhaust
aftertreatment system of the vehicle will determine when regeneration
is required. Mack Trucks, Inc., uses two exhaust aftertreatment system:
conventional and TRU
Conventional exhaust aftertreatment systems use passive-active regeneration.
The passive regeneration process oxidizes the particulates captured in the
DPF while the vehicle is in operation. An oxidation catalyst raises the exhaust
temperature to approximately 260°C (500°F), the temperature at which a
chemical reaction takes place to oxidize the soot (passive regeneration).
Conventional exhaust aftertreatment systems are used in highway and certain
vocational applications. TRU exhaust aftertreatment systems are used mainly
in refuse collection applications.
Depending on how the vehicle is set up, regeneration can occur while the
vehicle is being driven (referred to as a "moving" regeneration) or when the
vehicle is parked and idling (referred to as a "parked" regeneration).
206 Mack, US10 Emissions Solution
CAUTION
When active regeneration occurs (with either system), the temperature of the
exhaust will be elevated. DO NOT park the vehicle with the exhaust outlet under
low hanging overhead flammable objects such as trees, awnings, etc., that could be
damaged by elevated exhaust temperatures. DO NOT remove the diffuser.
CAUTION
If the vehicle is in a location that may be hazardous when an active regeneration
begins (i.e., in close proximity to flammable materials or gases), the regeneration
should be stopped by pushing the DPF switch to the "Stop Regeneration" position.
If an active regeneration is stopped by the vehicle operator, it should be initiated
at a later time when the vehicle is in a safe location. However, if an active
regeneration is stopped too many times, the vehicle may need to be taken to a
MACK service facility. The service facility will use a service tool to manually
initiate the regeneration.
WARNING
For chassis equipped with a heated dump body, be aware that temperature
around the area where the exhaust enters the body, as well as the product
contained in the body, may be elevated, particularly during DPF regeneration.
Extended Idling and Aftertreatment System
Conditioning
Extended idling performed on this vehicle equipped with an exhaust
aftertreatment system should be carried out at a low engine idle speed. There
is no benefit to using a raised engine idle speed for extended idling. The
only exception is for active PTO operation. Utilizing an engine speed above
1300rpm is recommended for vehicles which perform extended idling with an
active PTO.
During periods of extended idling, normally greater than 8hrs, the conventional
DPF system needs to perform a routine conditioning cycle. The conditioning
cycle is controlled by the Engine ECU and will start and stop automatically
as needed. The ATS conditioning is required to maintain normal exhaust
Mack, US10 Emissions Solution 207
aftertreatment system function and should not be stopped. ATS conditioning
will not occur on TRU DPF systems.
During these events the engine speed will increase to approximately
1050–1400rpm, for non-PTO operation, in order to complete the exhaust
aftertreatment conditioning cycle. Exhaust temperatures will also elevate
slightly but remain much lower than those reached during regeneration and
present no danger.
If a compatible driver display is available a message will be displayed when
the conditioning cycle is in progress. The message indicated in the driver’s
display will be "ATS Conditioning in Progress, No Action Required." If no driver
208 Mack, US10 Emissions Solution
display is available there will be no indication of an ATS conditioning event
except for the automatic increase in engine speed.
Exhaust Aftertreatment System
MRU Standard System View
W2031562
Mack, US10 Emissions Solution 209
1. Selective Catalytic Reduction (SCR)
Catalyst
2. Aftertreatment DEF Dosing Unit
3. Aftertreatment Diesel Particulate
Filter (DPF)
4.Aftertreatment DEF Tank
Diesel Exhaust Fluid (DEF) is a reactant
that’s key to the SCR process. It’s a
nontoxic, ultra-pure solution of urea and
ultra-pure water. Urea is a compound
of nitrogen that turns to ammonia when
heated. It is used in a variety of industries,
perhaps most commonly as a fertilizer in
agriculture. The fluid is non flammable,
and is not dangerous when handled as
recommended. However, it is highly
corrosive to certain metals, especially
copper and brass. Read the separate
section concerning the handling of DEF
solution.
Safety Information
Mack utilizes the use of a Diesel
Particulate Filter (DPF) and Selective
Catalytic Reduction (SCR) to meet
EPA2010 emissions. The system is
designed to require very little driver
interface to maintain correct operation.
The technology utilizes a passive
regeneration; requiring no fuel to be
injected to clean the DPF. In EPA2007 an
active regeneration (fuel was injected) was
required to clean out the DPF producing
very high exhaust outlet temperatures.
Certain vocational duty cycles will
require the use of fuel and/or a parked
regeneration to clean out built-up soot in
the particulate filter. Exhaust temperatures
will increase during a parked regeneration.
When parking the vehicle to perform a
parked regeneration keep away from any
flammable materials, vapors or structures.
DANGER
Exhaust gases and components can
be at extremely high temperatures
during regeneration. When parking the
vehicle, keep away from any flammable
materials, vapors, or structures.
DANGER
The temperature of the exhaust system
components during the regeneration
process can exceed 350 degrees C
(660 F). The exhaust gas leaving
the system can reach 505 degrees C
(930 F). Various factors (including
ambient temperature and duration of the
regeneration process) determine when
these components will return to normal
operating temperature after regeneration
has completed. Be extremely careful
around these hot components. Contact
with these components can result in
serious personal injury.
210 Mack, US10 Emissions Solution
Exhaust Aftertreatment System Components
and
Selective Catalytic Reduction (SCR)
Selective Catalytic Reduction (SCR) is an
emissions-reduction technology with the
ability to deliver near-zero emissions of
nitrogen oxides (NOx), a smog-causing
pollutant and greenhouse gas. SCR’s
performance has been proved in millions
of miles of real-world trucks in other
countries, as well as in long-term field
tests in the U.S.
SCR reduces NOx emissions to very low
levels, while at the same time delivering
excellent fuel economy and reliability.
The system doesn’t change the design
or of the basic engine. Rather, SCR is
an aftertreatment system which converts
NOx in the exhaust stream into harmless
gases. Modern diesels already use exhaust
aftertreatment systems, called diesel
particulate filters, to control emissions of
another pollutant, soot (also known as
particulate matter or PM).
SCR works by injecting Diesel Exhaust
Fluid (DEF) into the exhaust. DEF is a
solution of ultra-pure water and urea. DEF
works with the heat of the exhaust and a
catalyst to convert NOx into nitrogen and
water vapor - two harmless and natural
components of the air we breathe. The
end result is cleaner air, excellent fuel
efficiency and a reliable emissions control
system for today’s modern diesel engine.
W2031651
System Operation
1 Diesel engine optimized for high
performance, low particle emissions
and low fuel consumption.
2
Aftertreatment DEF tank
3
The Aftertreatment Control Module
(ACM) continuously monitors and
adjusts the DEF injection rate.
4
DEF is injected into the exhaust gases
in between the Aftertreatment DPF (5)
and the SCR catalyst (6).
5 Aftertreatment Diesel Particulate Filter
(DPF).
6
In the SCR catalyst, nitrogen oxides
are transformed into harmless nitrogen
gas and water.
7 The system notifies the driver when it
is time to refill tank with DEF.
Mack, US10 Emissions Solution 211
The Mack SCR system is simple and effective, with few components. It consists
of a Aftertreatment DEF tank positioned near the standard diesel tank, plus a
Aftertreatment DEF pump, Aftertreatment DEF Dosing unit and SCR catalyst.
The advantage of using DEF is that it enables the engine to use less EGR -- and
higher oxygen levels -- for better combustion, while meeting the EPA NOx emissions
requirement of 0.2 g/hp-hr NOx. By using DEF, we avoid the disadvantages of
increasing EGR to massive levels. This results in better fuel economy from your
Mack engine.
W2055490
Vertical SCR, side inlet
CAUTION
Do not put diesel fuel in the
Aftertreatment DEF tank. Diesel
fuel, if sprayed into the hot exhaust
along with the DEF, could ignite
explosively causing a fire resulting
in personal injury or damage to the
exhaust system.
212 Mack, US10 Emissions Solution
W3036787
Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid (DEF) is a reactant
that’s key to the SCR process. It’s a
nontoxic, ultra-pure solution of urea and
ultra-pure water. Urea is a compound
of nitrogen that turns to ammonia when
heated. The fluid is non flammable,
and is not dangerous when handled as
recommended. However, it is highly
corrosive to certain metals, especially
copper and brass. Read the separate
section concerning the handling of DEF
solution.
Use only Diesel Exhaust Fluid that is
clearly labeled as meeting ISO-22241
standards, and certified by the American
Petroleum Institute. The container must
display the API certification seal. Never
use agricultural or industrial grade
urea. Use of fluids other than API certified
Diesel Exhaust Fluid will compromise
aftertreatment system performance,
increase emissions, and may impact your
product warranties. Never dilute DEF
with water or any other fluid.
It is recommended that DEF not be stored
in extreme hot or cold conditions, or for
prolonged periods. Follow the instructions
for proper storage and handling as
indicated on the container or provided
with the purchase.
Note: Agriculture mixtures are not pure
enough for use in the SCR system and
impurities in the solution will comprise
the SCR system.
Mack, US10 Emissions Solution 213
Diesel Exhaust Fluid (DEF) Handling
When handling DEF solution, it is
important to prevent contact with
electrical connections. There is a risk that
the DEF will cause oxidation that cannot
be removed. Water or compressed air
do not help, since DEF quickly oxidizes
certain metal. If a disconnected connector
comes into contact with the DEF solution
it must be replaced immediately to prevent
the DEF solution from creeping further
into the copper wiring.
CAUTION
When detaching hoses and components,
do not spill DEF on disconnected
or unsealed connectors. If DEF is
spilled on a disconnected or unsealed
connector, the connector must be
replaced immediately.
Things to know about spilled Diesel Exhaust Fluid (DEF)
If DEF solution comes into contact with the skin: rinse with plenty of water and
remove contaminated clothing.
If DEF solution comes into contact with the eyes: rinse for several minutes and call
for medical help if necessary.
If inhaled: breathe fresh air and call for medical help if necessary.
Do not allow the DEF solution to come into contact with other chemicals.
The DEF solution is not flammable. If the DEF solution is exposed to high
temperatures, it breaks down into ammonia and carbon dioxide.
The DEF solution is highly corrosive to certain metals, including copper and brass.
If the DEF solution is spilled onto the vehicle, wipe off the excess and rinse with
water. Spilled DEF solution can form concentrated white crystals on the vehicle.
Rinse off these crystals with water.
Note: Do not flush DEF spillage into the
normal drain system.
Diesel Exhaust Fluid( DEF) Consumption
DEF consumption is related to fuel
consumption. A highway truck may travel
225–300 miles or more on one gallon of
DEF. A gauge much like a fuel gauge will
indicate the level of DEF in the tank. A
DEF low-level warning will activate when
DEF is low. If a driver runs out of DEF
completely, vehicle power will be reduced.
When the DEF tank is refilled, the engine
will resume normal power.
Diesel Exhaust Fluid (DEF) Availability
DEF will be available in 2.5-gallon
containers, 55-gallon drums, 275 gallon
IBC and in bulk storage for fleet locations,
truck stops and dealerships. All major
truck stops, dealers and distributors will
carry DEF.
DEF will freezes below –11 degrees
C (12 F). DEF needs to be protected
from extended periods of severe cold.
For more information on DEF and
availability please visit the website
www.Mackscr.com or please contact
Mack One-Call at 1–800–866–1177.
214 Mack, US10 Emissions Solution
Aftertreatment Diesel Particulate Filter (DPF)
CAUTION
Use of diesel fuel other than ULSD and
engine oils other than EO-O Premium
Plus (or VDS-4), will adversely affect
performance, efficiency and durability
of the Aftertreatment DPF system and
the engine, to the point where the engine
may not run at all. Manufacturer’s
warranties can also be rendered void due
to usage of improper fuel. Unapproved
fuel additives (including engine oil)
are NOT permitted. Blends of No.
1D and No. 2D grades of ULSD are
recommended and allowable for cold
weather operations.
The exhaust aftertreatment system
virtually eliminates exhaust smoke. White
exhaust vapor (water condensation) may
be visible during a cold start. If black
exhaust smoke is visible during engine
operation, this indicates a problem with
the exhaust aftertreatment system. Take
the vehicle to an authorized Mack Truck
dealer immediately.
Vehicles equipped with a 2010 emission
compliant engine have an exhaust
aftertreatment system which includes
a Selective Catalytic Reduction (SCR)
system and a Conventional or TRU
Aftertreatment Diesel Particulate Filter
(DPF). The Aftertreatment DPF takes
the place of the standard muffler, and it
reduces particulate emissions into the
atmosphere. Soot and other particulate
matter are collected by a filter where it is
eventually oxidized using a regeneration
process. Vehicles equipped with a
Aftertreatment DPF require the use
of EO-O Premium Plus (or VDS-4)
specification high performance diesel
engine oil and Ultra Low Sulfur Diesel
(ULSD) fuel.
Mack, US10 Emissions Solution 215
Aftertreatment Control Module (ACM)
The ACM also monitors the following
values in the exhaust aftertreatment
system:
W2029917
The ACM controls the following
components in the exhaust aftertreatment
system:
•
•
•
•
•
Aftertreatment DEF Dosing Unit
Aftertreatment DEF Tank Heater Valve
Aftertreatment DEF Line Heaters
•
•
•
•
Aftertreatment DEF Dosing Pressure
•
•
Aftertreatment DEF Tank Level Sensor
•
Aftertreatment DEF Tank Temperature
Aftertreatment DEF Tank Level
Aftertreatment DPF Inlet/Outlet
Temperature
Aftertreatment DPF Differential
Pressure
NOX Sensors
The ACM is a stand alone module.
Depending on your configuration it may
be mounted as part of the DEF tank (as
shown above) or on a bracket near the
DEF tank.
Aftertreatment DEF Pump
Aftertreatment DEF Return Valve
Aftertreatment DPF Regeneration
216 Mack, US10 Emissions Solution
Aftertreatment DPF Regeneration
Refer to the Exhaust Aftertreatment
System Information sun visor label
for additional Aftertreatment DPF
information.
W8056653
Mack, US10 Emissions Solution 217
Driver Warnings and On Board Diagnostics
(OBD)
On Board Diagnostics (OBD)
Beginning with your US 2010 compliant
Vehicle, On Board Diagnostics (OBD) is
introduced. This is very similar to the On
Board Diagnostics (OBD) system that has
been required on passenger cars for many
years.
On Board Diagnostics (OBD) is a
system that monitors the functions of
emissions related components and alerts
the vehicle operator to any detected need
for an emission related repair. When the
systems detects a needed repair to an
emissions related component it activates
the Malfunction Indicator Lamp (MIL).
The list of emissions related components
can be found in the Warranty and
Maintenance section of this manual.
218 Mack, US10 Emissions Solution
Instrument Cluster
The aftertreatment icons are located in the instrument cluster per the following images.
MRU Instrument Cluster
W3031622
A Left Side Indicator Set
B Right Side Indicator Set
1. Malfunction Indicator
Lamp (MIL)
2. CHECK Lamp
3. Aftertreatment DEF
Low Lamp
4. High Exhaust
Temperature (HEST)
Lamp
5. Aftertreatment DPF
Regeneration Required
Lamp
6. Aftertreatment DEF
Tank Gauge
Mack, US10 Emissions Solution 219
Instrument Cluster Icons
Aftertreatment icons are displayed on
the instrument cluster. There are 3
aftertreatment icons:
Aftertreatment DPF Regeneration
Required
High Exhaust System Temperature
(HEST)
Aftertreatment DEF Tank Low Level
Indicator
The Aftertreatment DPF Regeneration
Required icon flashes when the Diesel
Particulate Filter is becoming full/overfull
and regeneration is needed.
•
temperature during a moving regeneration.
When the HEST icon is illuminated, do
not park or operate the vehicle near people,
or any flammable materials, vapors, or
structures.
•
•
W3007444
High Exhaust System Temperature
(HEST) Icon
W2029416
W3007445
Aftertreatment DPF Regeneration
Required Icon
The High Exhaust System Temperature
icon illuminates when a parked
Aftertreatment DPF Regeneration is
initiated. It also indicates high exhaust gas
Aftertreatment DEF Tank Low Level
Indicator (DEF)
The Aftertreatment DEF Tank Low Level
Indicator icon illuminates when the fluid
level is low. It also Flashes when the level
becomes critically low.
Malfunction Indicator Lamp (MIL)
W3031200
MIL Lamp
•
MIL indicates government Regulation
On Board Diagnostics (OBD) faults
•
Lamp may remain active after repair
until system confirms repair
220 Mack, US10 Emissions Solution
Aftertreatment DEF Tank Level - Driver Warning
& Inducement
Aftertreatment DEF tanks are sized to
have no less than 2 times the diesel fuel
tank mileage or hour range
The vehicle instrument cluster has a
Aftertreatment DEF Tank Level Gage
Triggers
Aftertreatment
DEF Tank Low
Level Indicator
Amber Warning
Lamp
Inducement
>12%
Aftertreatment
DEF Tank Level
Gauge
None
None
None
None
None
None
25% torque
reduction
None
8 km/h (5 mph)
Road Speed Limit
(RSL)
<=12%
Aftertreatment
DEF Tank Level
Gauge
W2029416
0% Aftertreatment
DEF Tank Level
Gauge
W2029415
0%Aftertreatment
DEF Tank Gauge
Insufficient DEF
Pump Pressure
Diesel Fuel
Refueling >15%
W2029415
Note: Vehicle has to be stationary before
8 km/h 5 mph RSL becomes active.
Mack, US10 Emissions Solution 221
Aftertreatment DEF Quality - Driver Warning &
Inducement
Triggers
Aftertreatment
DEF Tank Low
Level Indicator
Amber Warning
Lamp
Good DEF Quality
None
None
Poor DEF Quality
DTC Initial
Detected
None
Inducement
None
None
W3031623
Poor DEF Quality
DTC Initial
Detected + 10
hours
None
25% torque reduction
W3031623
Poor DEF Quality
DTC Initial
Detected + 20
hours Diesel Fuel
Refueling >15%
None
Temporary Exit
from 5 mph
Inducement
None
8 km/h (5 mph) Road
Speed Limit (RSL)
W3031623
25% torque reduction
W3031623
Note: Vehicle has to be stationary before
8 km/h (5 mph RSL) becomes active.
222 Mack, US10 Emissions Solution
Exit conditions for DEF Quality "5 mph road speed limit" Inducement:
First Restart: Return to 25% torque reduction until proper DEF quality evaluation.
If poor DEF quality is detected during the next monitoring cycle then and 5 mph
resumed after vehicle stationary for 20 minutes. After the second restart a Service
Tool is required to exit the 8 km/h (5 mph) RSL.
Misfilling Diesel or Aftertreatment DEF Tanks
Although diesel fuel and Aftertreatment
DEF caps are clearly labeled and filler
necks and nozzles are different accidents
can happen.
Results of misfilling Diesel in
Aftertreatment DEF Tank
•
Contamination of fluids by- misfilling of
diesel or DEF in the wrong tank may result
in vehicle malfunction.
Aftertreatment SCR system may be
damaged by Diesel
•
SCR Catalyst may be damaged by
diesel (chemical damage)
Results of misfilling DEF in Diesel Tank
•
•
Emissions may be non-compliant
•
•
•
Engine may run poorly or not at all
Injectors may be damaged
Exhaust system corrosion may
occur between turbocharger and
Aftertreatment DPF
•
On Board Diagnostic (OBD)
Diagnostic Trouble Codes (DTC)
•
Costly repairs
•
On Board Diagnostic (OBD)
Diagnostic Trouble Codes (DTC)
Costly repairs
Note: DEF tank has a magnetic interlock
and fuel station DEF fluid dispensing
nozzle with a magnetic valve, have to meet
to prevent from dispensing into anything
other than the DEF tanks.
Mack, US10 Emissions Solution 223
SCR Tampering - Driver Warning & Inducement
1. Disconnected Aftertreatment DEF tank
level sensor
4. Disconnected Aftertreatment DEF
pump
2. Blocked Aftertreatment DEF line or
dosing unit
5. Disconnected SCR wiring harness
3. Disconnected Aftertreatment DEF
dosing unit
6. Disconnected NOx Sensor
Triggers
Aftertreatment
DEF Tank Low
Level Indicator
Warning Lamp
Inducement
No Tampering
None
None
None
Tampering DTC
Pending
None
None
W3031623
Tampering DTC
Confirmed
None
None
W3031623
Tampering DTC
Initial Detected +
10 hour
None
25% torque
reduction
W3031623
Tampering DTC
Initial Detected +
40 hours Diesel
Fuel Refueling
>15%
None
Note: Operator can not override the 8
km/h 5mph road speed limit.
8 km/h (5 mph)
road speed limit
W3031623
Note: Vehicle has to be stationary before
8 km/h (5 mph RSL) becomes active.
224 Mack, US10 Emissions Solution
Warranty and Maintenance
Exhaust Aftertreatment System Maintenance
The vehicle must be taken to an authorized
Mack Truck dealer to remove the ash from
the Aftertreatment Diesel Particulate Filter
and clean the Aftertreatment Doser.
Engine Maintenance Intervals
Component
Interval
Fuel Filter
Change
Every oil change. Under certain
conditions (for example, irregular
fuel quality), the fuel/water separator
filters may require more frequent
replacement.
Air Cleaner
Change
Control lamp indication or 24
months, whichever comes first
Valve and Injector Lash
adjustment , MP7 and
MP8
Initial Adjust
200 000 km (125,000 miles) or 12
months, whichever comes first
Injector Lash Adjustment ,
MP7 and MP8
Adjust
Every 400 000 km (250,000 miles) or
24 months, whichever comes first
Aftertreatment DPF Ash
Cleaning
Clean
400 000 km (250,000 miles) or 4,500
hours, whichever occurs first
Aftertreatment Doser
Clean
240 000 km (150,000 miles) or 4,500
hours, whichever occurs first
Aftertreatment Diesel
Exhaust Fluid (DEF) Filter
Change
First change at 161 000 km (100,000
miles) 3200 hours or 3 years
whichever occurs first, 241,000 km
(150,000 miles) 4800 hours or 3
years there after
Aftertreatment Diesel
Exhaust Fluid (DEF) Filler
Neck Filter
Clean
280 000km (175,000 miles) or 12
months, whichever comes first
MAINTENANCE AND LUBRICATION 225
MAINTENANCE INTRODUCTION
Preventive maintenance is vital to the life of your new vehicle. This section of
the Operator’s Handbook covers items of importance concerning the proper
care of MACK vehicles. A well-run maintenance and lubrication program is
the best way to ensure a long life of productive operation.
The operator plays an important role in the proper care of this equipment. By
performing daily checks and observing the equipment while in operation, minor
defects can be caught and corrected before they become major problems.
Make sure any problems are corrected before putting the equipment into
operation.
If you have any questions concerning the proper care, maintenance and
lubrication of your vehicle, or if you need help in developing a preventive
maintenance program, contact the service manager at the local MACK Sales,
Parts and Service Center.
Note: This handbook contains basic maintenance information. For complete
maintenance and lubrication procedures, refer to the Maintenance and Lubrication
Manual .
TURBOCHARGER
The engine turbocharger operates at very high speed, temperatures and
pressure. Turbo bearing lubrication is critical, particularly for a newly installed
turbo or one which has not been operated for a period of time and all oil has
drained from the bearing and shaft surfaces. To avoid turbocharger bearing
failure, the following instructions are recommended:
• Start the engine at least every 30 days to ensure turbo bearing lubrication.
Operate engine at low idle for at least three minutes before increasing RPM
or driving the vehicle.
• If the engine has not been run for more than 30 days, turbo pre-lube
procedure is necessary:
1. Remove turbo air intake duct and oil line connection at turbo.
2. Fill oil inlet fitting to overflow with clean engine oil.
3. Using fingers at compressor wheel, carefully spin and wiggle the turbo
shaft to distribute the oil over all bearing surfaces.
4. Reconnect air intake duct and again fill turbo oil port to overflow, connect oil
line and start engine.
5. Operate engine at low idle for at least three minutes before increasing
RPM or driving the vehicle.
226 MAINTENANCE AND LUBRICATION
CLEANING YOUR VEHICLE
The best protection against environmental influences that can hurt your
vehicle’s finish is frequent washing and waxing. How often this is required
depends on how much the vehicle is used, where it is parked and weather
conditions. Frequent washing is required to remove oils, dirt and grime that
can stain and oxidize the painted and polished surfaces of your new truck.
Exterior Washing
Recommendations for the first 30 days...
• Only wash the vehicle by hand with cool water, a mild car wash solution and
a soft cloth or sponge. Do not use a commercial truck wash.
• Wash the vehicle in the shade, never in direct sunlight.
• Do not dry wipe the finish; always use clean water. Dry wiping could scratch
the finish.
• Do not park near factories with heavy smoke fallout for extended periods
of time.
• Bird droppings have high acid content and can damage freshly painted
surfaces. They should be cleaned off as soon as possible.
• Do not spill gasoline, diesel fuel, oil, antifreeze, transmission fluid or any
solvents of the like on the new finish. If you do, IMMEDIATELY rinse off with
water. DO NOT WIPE.
• Do not scrape ice or snow from surface. Brush off the loose material with a
soft snow brush.
Recommendations for the first 90 days...
• Do not wax or polish the vehicle; this will allow the finish to dry and harden
completely. (Do not use waxes or polishes that contain silicone.)
Note: Do not wash the vehicle in direct sunlight.
DANGER
Test the service brakes after washing the vehicle. Moisture and/or ice on the
brakes can affect braking efficiency.
Note: When washing the vehicle in cold/freezing weather, avoid direct water spray
into the door lock cylinders, as the water may freeze in the lock mechanisms.
MAINTENANCE AND LUBRICATION 227
CAUTION
Proper care of the paint finish is an important part of the durability. Chemicals
used to wash the paint should be of neutral pH with a range of between 6 and 8.
Detergents containing butyl cellosolve or potassium hydroxide should not be used.
Note: Vehicles should be washed only in special wash bays to protect the environment
from cleaning agent contamination.
DANGER
Vehicle cleaning products must be handled carefully, as these products may be
poisonous. Keep all cleaning products out of the reach of children.
WARNING
Do not clean the underside of the fenders, cab, chassis, etc., without protecting
the hands and arms, as injuries may result when scraping against sharp edges.
CAUTION
For chassis used in concrete operations, do not use muriatic acid or similar types
of products to clean concrete from the cab or frame surfaces. Use of these types of
products will damage the paint finish and void the vehicle warranty. Mack Trucks,
Inc. has approved EL-ReadyMix Truck Wash & Wax for removing concrete from
the vehicle surfaces. This product is available on a direct ship basis from EMS®.
For additional information, contact EMS® at 800-510-8812, or on their web site
at www.enviromfg.com.
Note:
Unprotected aluminum surfaces will form an oxide layer if not maintained.
This is especially important during cold season when roads are salted or in coastal
areas where the salt level in the air is high. Clean with steam or high pressure water.
Use a mild detergent if the dirt is heavy. Rinse well. Clean aluminum surfaces
with warm water. If the surface has heavy dirt or tar spots, use a tar remover. To
prevent spotting, wipe aluminum surfaces dry after washing. The use of an aluminum
protective Carnuba-based wax is recommended after washing for longer term
protection from road salts and spotting.
228 MAINTENANCE AND LUBRICATION
Cab and Hood
• Soften the dirt on your cab with plenty of water and rinse.
• Clean truck with a soft sponge/brush starting at the roof and working
downward using slight pressure.
• Use mild detergent. Never use strong soaps or chemical detergents. Any
commercially available cleaner designed specifically for automotive finishes
may be used for cleaning the cab and hood surfaces. The 3M company and
Mequiar’s® have a complete line of automotive cleaning products available
that are approved for use on MACK vehicles.
• Rinse the sponge or brush often to keep it clean.
• If possible, clean wheels and dirtier areas with a separate sponge/brush.
This will help avoid scratching body paint with grit from other areas.
• Rinse truck thoroughly with water and wipe dry with a soft clean chamois or
all cotton towels to avoid surface scratches and water spotting.
CAUTION
Do not clean the underside of the fenders, cab, chassis, etc. without protecting your
hands and arms. You may injure yourself on sharp-edged parts.
Chassis
• Wash away excess dirt and grime with water from a hose.
• Use a mild detergent/soap and a soft brush to remove road grime and salts
that can collect on the frame.
• Rinse thoroughly with a hose.
Note: Cleaning of your chassis on a regular basis will help deter accelerated corrosion
and rust on the frame and components. Chemicals used for ice and snow removal and
dust control can collect on the frame. If these are not removed in a timely manner,
accelerated corrosion can occur on fuel lines, frame, and other components even
though they have corrosion protection.
MAINTENANCE AND LUBRICATION 229
Cab Interior
• For cleaning vinyl upholstery and lining: wipe with a soft cloth, using a good
commercial upholstery cleaner. Do not use acetone, lacquer thinner, etc.
• For cleaning fabric upholstery: use an upholstery shampoo specially
designed for this purpose. Follow the directions on the manufacturer’s label.
Waxing
• Always use waxes and polishes that are non-abrasive. Do not use waxes or
polishes that contain silicone.
• When water does not form small drops and roll off clean paint, apply a coat
of good hard wax.
• Even if a liquid wax solution is used on a regular basis, it is advisable to
protect the finish with a hard wax at least twice a year.
• Your truck may have a basecoat plus clearcoat. Use a basecoat/clearcoat
wax on your paint finish.
Polishing
Polish your truck only if the paint has lost its shine and the gloss cannot be
brought back with wax. It is recommended to have a professional polish your
truck to avoid swirl marks or damage to the painted surface. Mequiar’s® has a
complete line of waxes, polishes and other cleaning and care products that
are approved for use on MACK cabs, hoods and sleeper surfaces.
Winter Warnings
• If you rinse your vehicle with a hose, avoid direct water into lock cylinders.
You may experience freezing of the lock mechanism.
• Test brakes after each vehicle wash. Moisture and ice on brakes can affect
braking efficiency.
A well kept vehicle can look like new after many years of service. Proper
care and maintenance can help you keep your vehicle’s beauty and value.
You can get an assortment of Mack Trucks approved cleaning products from
your local Mack dealer.
230 MAINTENANCE AND LUBRICATION
TOWING
Tow pins, hooks, eyes, etc., are located in or behind the front bumper. These
devices meet the recommendations for towing set forth by the Technology and
Maintenance Council (TMC) of the American Trucking Association and can be
used for towing a disabled vehicle from the immediate location.
If it is necessary to remove the tow pin, remove the retainer clip first. Once the
retainer clip is pulled, the tow pin can be lifted out of the bumper hole.
CAUTION
Do NOT lift and tow any vehicle by tow pins, hooks, eyes, etc. If the vehicle is mired
in heavy mud, snow, etc., use a suitable sling-type towing arrangement.
Note: Tow pins, hooks, eyes, etc., are NOT intended for use as long-term towing
devices.
CAUTION
Failure to disconnect the driveshaft, remove the drive axle shaft(s) or lift the drive
wheels off the ground before towing or pushing the vehicle, can cause serious
transmission damage.
DANGER
If the drive shaft has been removed for towing, DO NOT reuse bearing retainer
bolts or stamped strap bolts, or stamped straps. Reuse of bearing retainer bolts
or stamped strap bolts, or stamped straps can cause driveline failure, which can
result in separation of the driveline from the vehicle. A separated driveline can
result in property damage, serious personal injury or death.
MAINTENANCE AND LUBRICATION 231
C0029644
ENGINE OIL LEVEL CHECK
As the operator of this vehicle, it is important for you to perform the daily
inspections necessary to keep your truck in good shape. Maintaining the
proper oil level in your engine crankcase cannot be overemphasized.
Before checking the oil, remember these important points:
• Measurement of the oil level must be taken on level ground.
• The best time to check oil level is while the engine is COLD (prior to starting
at the beginning of the work day, or after the vehicle has sat approximately
2 hours). At normal operating temperature (engine oil temperature above
79.4°C [175°F]), oil level can be checked 15 minutes after shut down.
CAUTION
Failure to wait a sufficient amount of time (2 hours if engine oil temperature is
below 79.4°C [175°F]) or 15 minutes if oil temperature is above 79.4°C [175°F])
will result in an inaccurate dipstick reading.
• The level must be close to the FULL line (at least between the ADD and
FULL lines) on the dipstick, but must NOT exceed the FULL line (refer to
illustration below).
232 MAINTENANCE AND LUBRICATION
C0029422
Power Steering Reservoir
The Power Steering system uses only DEXRON® type automatic transmission
fluid.
MAINTENANCE AND LUBRICATION 233
C0029702
Power Steering Reservoir
1. Power Steering Reservoir
For additional information about power steering, refer to the Maintenance
and Lubrication Manual
234 MAINTENANCE AND LUBRICATION
FUEL TANK
Your vehicle may be equipped with an isolated fuel tank. If so equipped, the
following label will be affixed to the fuel tank decal.
C0029424
Fuel Tank Cap
Use MACK approved non-vented cap only or tank damage and/or poor engine
performance may result. DO NOT fill to more than 95% of liquid capacity.
MAINTENANCE AND LUBRICATION 235
FUELING
DANGER
DO NOT carry extra fuel containers in the cab. Fuel containers, full or empty,
may leak, explode or give added fuel to a fire. Failure to follow this precaution
may lead to serious personal injury or death.
DANGER
DO NOT smoke while fueling the vehicle. The glow from the cigar/cigarette can
ignite the diesel fuel, causing an explosion resulting in serious personal injury
or death.
DANGER
Do not remove the fuel tank cap near an open flame. Diesel fuel vapors are
combustible and can cause an explosion or fire, resulting in severe personal
injury or death.
CAUTION
Diesel-powered engines for heavy-duty trucks built on or after January 1, 2010 are
designed to operate only with Ultra Low Sulfur Diesel (ULSD) fuel. Improper
fuel use will reduce the efficiency and durability of engines, permanently damage
advanced emissions control systems, reduce fuel economy and possibly prevent the
vehicles from running at all. Manufacturer warranties will be voided by improper
fuel use. Additionally, burning Low Sulfur Diesel fuel (instead of ULSD fuel) in
2007 and later model year diesel-powered cars, trucks and buses is illegal and
punishable with civil penalties.
236 MAINTENANCE AND LUBRICATION
CAUTION
Ultra Low Sulfur Diesel (ULSD) fuel with a maximum sulfur content of 15 ppm
must be used in order to meet Euro4 engine emission requirements.
Using otherwise approved diesel fuels with a maximum sulfur content greater than
500 ppm may shorten engine life and void the engine warranty.
Air is always present inside the fuel tanks, entering mainly through the tank
ventilation. With the air being heated and cooled, condensation is formed and
water is mixed in the fuel. To avoid condensation when the vehicle is parked
for longer periods, fill the tanks up to 95% of capacity. Do not fill more than
that, as the fuel needs to have room for expansion during the heat of the day.
BioDiesel
Soy Methyl Ester (SME or SOME) BioDiesel fuel in blends up to a B5
concentration (5% blend) is approved by Mack Trucks, Inc.
Note: Although higher concentrations are available, concentrations up to B5
(maximum) are the only blends currently approved by Mack Trucks, Inc.
Note: MACK Engines are certified to comply with U.S. EPA and California Air
Resources Board (CARB) emissions standards based on the use of reference test
fuels commonly available in the United States and specified in this manual. Use of
alternative fuels, including BioDiesel, may affect engine emissions. Mack Trucks,
Inc. does not warrant, and is not responsible for ensuring that the engines will comply
with U.S. EPA and CARB emissions standards.
B5 Approval For Mack US10 Certified Products
Mack engines are certified to comply with U.S. EPA and California emissions
standards based upon the use of test fuels with specifications established by these
regulatory agencies. Alternative fuels, including biodiesel, that are not substantially
similar to the required test fuels may adversely affect engine emissions compliance
and may impact the performance of certain emissions aftertreatment components. As
a result, Mack does not warrant the engine will conform to applicable Federal or
California emissions limits when operated on, or having operated on, biodiesel or
other alternative fuels that are not substantially similar to specified test fuels used for
certification.
The use of biodiesel up to a maximum of 20% (B20) in and of itself, will not affect
the manufacturers mechanical warranty as to engine and emissions system related
components except as limited below with respect to aftertreatment components,
provided the bio fuel used in the blend conforms to ASTM D6751 and B1 to B5
MAINTENANCE AND LUBRICATION 237
blends conform to ASTM D975, and B6 to B20 blends conform to ASTM D7467.
Failure of cetain emissions aftertreatment components, specifically SCR, DPF and
NOx sensors will not be warranted if the failure can be attributed to operation on
biodiesel blends from 6 to 20% (B6 to B20) even if the biodiesel used in the blend B6
to B20 conforms to ASTM D7467 or any related standard.
238 MAINTENANCE AND LUBRICATION
COOLING SYSTEM
The cooling system is a pressurized system. The coolant is circulated by a
centrifugal pump. It is a typical system in most respects, but there are a few
things to keep in mind when checking or working on the cooling system.
Note: There is an auxiliary radiator located behind the cab that includes electrically
operated fans. The fans may begin to run at any time without warning. Keep clear of
fans.
WARNING
Keep clear of fan when engine is running. Fan may start to rotate at high
speed without warning.
WARNING
Avoid injury when checking coolant in a hot engine. Wait for the engine to
cool prior to checking the level whenever possible.
Coolant Level Check
WARNING
Turn the cooling system pressure cap counterclockwise to the first stop but do
NOT depress. After the pressure has completely dissipated, press the cap
downward and continue turning to remove.
Your MACK model chassis has a pressurized surge tank is mounted on
the EATS rack. Coolant should be visible in the sight glass (see arrow in
illustration) located on the side of the tank.
MAINTENANCE AND LUBRICATION 239
W2056631
Draining the Cooling System
Whenever repairs are to be made which would require disconnection of
coolant hoses, etc., the cooling system should be drained. Carefully remove
the filler cap and remove all pipe plugs.
Refilling the Cooling System
Close all drain cocks and fill with the proper coolant mixture. Run engine
with the pressure cap removed until operating temperature is reached and
the thermostat opens. Recheck level and add coolant if required. Run the
engine long enough to be sure the system is free of air and has the correct
amount of coolant.
240 MAINTENANCE AND LUBRICATION
Protecting the Cooling System
CAUTION
The concentration of ethylene glycol or propylene glycol in the cooling system must
be checked with a refractometer prior to traveling or operating in areas where
subfreezing temperatures may be encountered. When adding antifreeze to the
system, run the engine for 20 minutes before checking with a refractometer.
Note: Your chassis is currently supplied from the factory with engine coolant
protection to –23°C (–10°F). Optional coolant protection to –40°C (–40°F) is also
available.
Ethylene glycol or propylene glycol-based antifreezes are both approved for
all MACK engines. All ethylene glycol and propylene glycol coolants must
be low-silicate antifreezes which meet ASTM4985 test (GM6038M SPEC)
criteria. These antifreezes are sometimes referred to as heavy-duty diesel
coolants. Passenger car coolants do NOT meet this specification.
Be sure to maintain the required level of antifreeze protection for anticipated
winter temperatures in your area of operation. A 40% to 60% concentration of
antifreeze is required for MP engines, regardless of application, geographic
location or ambient air temperature.
CAUTION
Do NOT exceed a 60% concentration of antifreeze to water. A higher percentage of
antifreeze will not increase protection. Concentrations over 60% adversely affect
freeze protection and heat transfer rates.
Note: Propylene glycol should be checked with a refractometer.
Note: ALWAYS mix the water/antifreeze solution before pouring it into the cooling
system.
Note: The piping arrangement may cause capacity variation depending on the type
of cooling system and optional external cooling devices which may be attached.
Therefore, it is difficult to tell exactly how much coolant it will take to fill any one
particular system.
MAINTENANCE AND LUBRICATION 241
CAUTION
Do NOT use coolant solutions which contain anti-leak additives in trucks equipped
with coolant filters or conditioners.
CAUTION
Do NOT use soluble oil-type coolants in any MACK cooling system.
Cooling System Maintenance
The cooling system must be maintained by performing regularly scheduled
maintenance as outlined in the Maintenance and Lubrication Manual. Cold
weather operations, however, place added demands on the cooling system.
Prevent potential cold weather problems by performing a quick check of the
cooling system as outlined below:
• Make a general check for cooling system leaks.
• Inspect hoses and clamps for leaks and condition. Tighten hose clamps to
specifications (as required).
• Check coolant level. Add fresh coolant (in specified concentration) as
necessary.
• Check and record degree of antifreeze concentration. Add antifreeze as
necessary to obtain required protection level.
For additional information concerning the cooling system, refer to the
Maintenance and Lubrication Manual.
242 MAINTENANCE AND LUBRICATION
Accessory Drive Belt Routing
The following diagram shows the accessory drive belt and main belt routing
with and without air conditioning. This diagram is located in a clear area on the
outside of the left frame between the radiator and center line of the front axle.
C0029647
Accessory and Main Drive Belt Routing
1. Accessory and Main Drive Belt Routing MP7 Engine
Accessory Drive Belt Routing
The following diagram shows the accessory drive belt and main belt routing
with and without air conditioning. This diagram is located in a clear area on the
outside of the left frame between the radiator and center line of the front axle.
MAINTENANCE AND LUBRICATION 243
C0029426
Accessory and Main Drive Belt Routing
1. Accessory and Main Drive Belt Routing MP8 Engine
244 MAINTENANCE AND LUBRICATION
HEADLIGHTS
Bulb Replacement
Note: This vehicle uses a sealed beam type headlamp bulb which is replaceable
without special tools.
WHEELS
Wheel Inspection
Look at the wheels and cap nuts. Inspect them for evidence of cap nut
looseness. Rust streaks from the cap nut ball seat are an indication of
looseness. Refer to the Maintenance and Lubrication Manual for complete
procedures concerning wheel inspection and wheel nut tightening.
C0029431
Look for cracks around the hand hole, stud hole and wheel. Look for broken
studs, wheel damage or improperly seated lock rings.
C0029432
MAINTENANCE AND LUBRICATION 245
Tires
DANGER
Tires used on multipiece rims must be assembled and inflated only by experienced,
qualified personnel. Tires must be inflated in a safety cage whenever possible. If,
however, a safety cage is not available, use a portable lock-ring guard. The tire
must be deflated prior to removal of the tire-and-rim assembly from the vehicle.
Remove the valve core to ensure complete deflation.
DANGER
NEVER position your body in front of the rim during inflation.
CAUTION
NEVER use water-based sealants, puncture proofing, or liquid balance materials
containing water in All-Steel Radial Ply truck tires.
Inflation Pressure
To ensure maximum mileage and overall performance from your tires, it is
essential that they operate at the correct inflation pressure for the load carried.
Inflation pressure should be checked daily while the tires are cold. Always use
an accurate tire pressure gauge. NEVER bleed air from a hot tire, as it will
then be underinflated. Refer to the specific tire manufacturer’s data books, or
to the vehicle certification label for a complete listing of tire inflation pressures.
For additional information concerning tire care, refer to the Maintenance and
Lubrication Manual .
WARNING
UNDER NO CIRCUMSTANCES should you drive on underinflated or
overloaded tires. A tire in this condition builds up excessive heat which can
result in sudden tire destruction, property damage and personal injury.
246 MAINTENANCE AND LUBRICATION
CAUTION
Never bleed air from your tires in an attempt to gain traction for a vehicle stuck
in snow, ice or mud. This practice provides no additional traction and typically
results in underinflated tires. Never bleed air from a hot tire since that tire will
then be underinflated.
To adjust for pressure fluctuations induced by temperature changes associated
with winter weather, it is recommended that tire inflation pressure be checked
daily when the tires are cold (i.e., before the vehicle is driven). Always use an
accurate tire pressure gauge.
Inspection
Inspect your tires daily. Look for bulges, cracks, cuts, penetrations and/or
oil contamination. If any such damage is found, the tire must be thoroughly
inspected by a qualified tire inspector and repaired or discarded immediately,
at his discretion. Also, check for uneven wear. If found, a thorough inspection
of front end parts and alignment should be made by a qualified mechanic.
Refer to the Maintenance and Lubrication Manual for more information.
Tire Manufacturer’s Data Book
Specific and more detailed information can be obtained by referring to the
technical data books provided by each tire manufacturer.
CAUTION
For important tire information (i.e., high speed limits, inflation pressures, etc.),
consult the product information available through the specific tire manufacturer.
Oil Contamination of Tires
Lubricating oils, fuel oil, gasoline and other petroleum derivatives, if allowed
to contact tires, will soften the rubber and destroy the tire. Preventive
maintenance is necessary to ensure that oil leakage does not occur. The
following areas should be inspected on a regular basis:
• Axle end seals
• Engine seals
MAINTENANCE AND LUBRICATION 247
• Transmission seals
• Drive axle seals
• Oil filters
• Oil and hydraulic lines (if equipped)
• Refer to the Maintenance and Lubrication Manual , specific tire
manufacturer’s books, or to the vehicle certification label, for additional
information concerning tires and their care.
248 MAINTENANCE AND LUBRICATION
BATTERY
CAUTION
To avoid damage to sensitive electronic equipment, disconnect ALL battery cables
and harnesses to electronic control units before welding. Do NOT disconnect
batteries while engine is running.
Jump-Starting Engine
If you encounter a situation in which it is necessary to jump-start an engine,
use the following procedures.
WARNING
Batteries which are to be linked together must be of the same voltage (12 to
12, 24 to 24). Take care to observe proper polarity when connecting batteries.
Batteries produce explosive gases. Keep sparks, flames, cigarettes, etc., away
from batteries at all times. Protect your eyes by wearing safety goggles. Be
sure vehicles are NOT touching each other.
CAUTION
To avoid damaging any electronic controllers when jump-starting a V-MAC vehicle,
always turn the ignition switch OFF before connecting the batteries.
1. Connect the positive (+) cable to positive (+) post of discharged battery or
to the positive post of the remote jump-start connector (if equipped).
2. Connect the other end of the same cable to the positive (+) post of the
booster battery.
3. Connect the second cable, negative (-) side, to the other post of the booster
battery.
4. Make the final connection to the negative (-) battery terminal or the remote
jump-start connector (if equipped) of the stalled vehicle, and stand back.
5. Start the vehicle with the booster batteries and then start the stalled vehicle.
Shut down the vehicle with the booster batteries and remove the cables in the
reverse order of connection.
MAINTENANCE AND LUBRICATION 249
WARNING
Do NOT connect the final negative (-) connection to the frame of the stalled
vehicle. This would cause all current to flow through the master ground circuit
breaker resulting in overload.
ELECTRICAL
Circuit Breaker and Relay Panels
The electrical equipment cover for this vehicle is located between the drive
and passenger seats in the engine tunnel.
The cover panels are fastened with screws. Most relays and fuses are
accessible from under the top cover. Since the function of some fuses or
relays may change for the vehicle operation, refer to the list of functions that is
attached beneath each panel.
250 MAINTENANCE AND LUBRICATION
C0029703
MAINTENANCE AND LUBRICATION 251
C0029704
252 MAINTENANCE AND LUBRICATION
C0029705
Note: For circuit breaker designations, refer to the Circuit Protection charts.
Fuses are standard equipment for all circuits except the headlamps and
windshield wipers. Circuit breakers are available as optional equipment.
CAUTION
For proper installation of electrical accessories, all wiring should meet SAE
requirements and be routed through the circuit protection panel with proper
amperage fuses or Type II circuit breakers. (Headlights and wipers will be on
Type I, cycling-type circuit breakers.)
MAINTENANCE AND LUBRICATION 253
Some vehicles may be equipped with daytime running lights. For the daytime
running lights to be operational, a DRL module must be installed in the
relay socket marked either DRL MOD or Running Lamps on the electrical
equipment panel. Do NOT install a standard relay into the daytime running
light relay socket (marked either DRL MOD or Running Lamps) or a short
circuit in the headlight high beam circuit will result.
The headlight circuits are protected by SAE Type I (automatic reset-cycling)
circuit breakers that automatically interrupt then restore the flow of current
through the circuit in the event of an overload. This cycling will continue until
the cause of the overload is repaired.
SAE Type II (automatic reset, non-cycling) circuit breakers (if equipped)
provide a complete circuit disconnect until the overload is corrected. The
power to the affected circuit breaker must be shut off before the circuit breaker
will reset itself.
The circuit protection panel also provides access to battery, ignition and
ground terminals for non-factory installed electronic equipment. (On V-MAC
chassis, there are two serial link terminals for easy local connection of a trip
recording device.)
Electrical Grease
To prevent corrosion of the lamp socket terminals, particularly with the
clearance and marker lamp, apply a coating of electrical sealing grease, such
as Lubriplate DS-ES or TEK-519, to the socket and terminal assemblies.
CAUTION
Do not use electrical grease on any V-MAC connectors.
254 MAINTENANCE AND LUBRICATION
Circuit Protection Charts
Cab Circuit Protection (V-MAC IV)
CB2 — 15A
CB3 – 15A
CB4 – 20A
F5 – 10A
Headlamps Hi
Beam
Park & Tail Lps.
Turn Signals
Flasher
Tractor
Emergency Stop
Lps.
F6 – 10A
F7 – 10A
F8 – 15A
F9 – 15A
Dome Lps.
Courtesy Lps.
Key Switch
Air Sol.
CB Posts
F10 – 5A
F11 – 15A
F12 – 15A
F13 – 15A/20A
Diag. Conn.
Battery Stud
Battery Stud
ABS Battery
F14 — 30A
F15 – 15A
F16 – 10A
F17 – 10A
Aux. Fan Cool
Beacon Lamps
VECU EMS
Power
VECU Ctrl. Sw.
Input
F18 — 10A
F19 — 5A
F20 – 10A
CB21 – 20A
DCL EMS Power
Instrument
Cluster Battery
Moto Mirrors
LH Windshield
Wiper & Washer
CB22 — 20A
CB23 – 10A
F24 – 15A
F25 – 30A
RH Windshield
Wiper & Washer
WS
Wiper/Washer
2 Way Radio Opt.
HVAC Cab Unit
F26 — 15A
F27 – 15A
F29 – 10A
F30 – 10A
Rear Flood
Ignition Stud
EMS Relay
Munc. PTO
Opt. Ign.
F31 — 10A
F32 – 15A
F33 – 20A
F34 – 30A
Trans. Ign.
Body Builder
Battery 2
Trailer Stop Lps.
Reverse/Neutral
Power
MAINTENANCE AND LUBRICATION 255
Cab Circuit Protection (V-MAC IV)
F35 — 25A
F36 – 15A
F37 – 25A
F38 – 30A
Cab & Trailer
Clearance Lamps
Horn
Trailer Tail Lamp
Engine Ctrl. Unit
F39 — 30A
F40 – 25A
F41 – 15A
F42 – 10A
Trailer ABS
Power
Body Ignition
Stud
Engine Acc.
Back-Up Lamp
F43 — 15A
F44 – 20A
F45 – 30A
F46 – 10A
Eng. Comp #2
Heat/Air Dryer
Fuel Heater
Power Outlet
F47 — 15A
F49 – 10A
F50 – 10A
F51 – 10A
Spare EMS
ABS Ignition
Head Lamp Left
Head Lamp Right
Low B
F52 — 15A
F54 – 20A
F55 – 20A
F56 – 10A
Spare Brake
Wear
DPF Battery
Heated Mirror
Telma
F57 — 15A
F58 – 5A
F60 – 15A
F61 – 20A
HVAC Roof Unit
L-R Relay Ctrl.
Engine Comp #1
Body Battery
Stud
F62 — 30A
F63 – 5A
F64 – 10A
F65
Aux. Fan Cool
Package
Instrument
Cluster (EMS)
DPF Ignition
Open
F66 — 15A
F67
F68 – 15A
F69
Spare Ign.
Open
Cigar Lighter
Open
F71 — 10A
F74 – 5A
Trans. Battery
Radio Mem.
256 METRIC CONVERSIONS
METRIC CONVERSIONS
Note: Use all tools on the fasteners they were made to be used on. Use metric tools
on Sl metric units only. Never try to use metric tools on U.S. standard fasteners or
U.S. standard tools on Sl metric units.
CAUTION
Potential external/internal thread mismatch condition(s) may occur with certain
metric thread-inch thread fastener combinations, and with fastener combinations
involving incompatible metric fastener systems. A given thread mismatch condition
can result in thread stripping and/or assembly weakness leading to potential service
failure, thereby rendering a vehicle non-operational and/or unsafe for operation.
The specific external/internal thread combinations from which such problems can
result are identified and set forth in Maintenance and Lubrication Manual
METRIC CONVERSIONS 257
SI to U.S. Conversions
25.4 millimeters
=
1 inch
1.61 kilometers
=
1 mile
.473 liter
=
1 pint (U.S. liquid)
.946 liter
=
1 quart (U.S. liquid)
.01639 liter
=
1 cubic inch
1.3558 Newton meters
=
1 pound-foot
.746 kilowatt
=
1 horsepower
6.895 kilopascals
=
1 pound/square inch
(1.8 x degrees Celsius) + 32
=
degrees Fahrenheit
.83267 Imperial gallon
=
1 gallon (U.S. liquid)
U.S. to SI Conversions
.03937 inch
=
1 millimeter
.6214 mile
=
1 kilometer
2.1134 pints (U.S. liquid)
=
1 liter
1.0567 quarts (U.S. liquid)
=
1 liter
61.024 cubic inches
=
1 liter
.7376 pound-foot
=
1 Newton meter
1.34 horsepower
=
1 kilowatt
.145 pound/square inch
=
1 kilopascal
.556 x (degrees Fahrenheit -32)
=
degrees Celsius
1.2009 gallons (U.S. liquid)
=
1 Imperial gallon
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