Mack Pinnacle Series (CXU)

Mack Pinnacle Series (CXU)
OPERATOR’S
HANDBOOK
OPERATOR’S HANDBOOK
•
Mack CXU
®Mack Trucks 2014
Printed in U.S.A.
22470031
22470031
Mack® Pinnacle™ Series
(CXU)
JUNE 2014
22470031
Foreword
DO NOT Remove this manual from the vehicle. It contains important
operational and safety information that is needed by all drivers and
owners of this vehicle.
This manual contains information concerning the safe operation of
your vehicle. It is extremely important that this information is read
and understood before the vehicle is operated. This manual also
contains a considerable amount of information concerning the vehicle,
such as vehicle identification . Please keep this in the vehicle at all
times. Information from other component manufacturers is supplied
in separate manuals in the Owners Package.
Note: It is important that this manual stay with the vehicle when it
is sold. Important safety information must be passed on to the new
customer. The service information contained in this manual gives the
owner important information about maintaining the vehicle.
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 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: PV776-22470031
©2014 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............................................................................................................5
Engine Identification..................................................................................................6
Engine Information Plate ...........................................................................................7
Clean Idle Engines .....................................................................................................8
Transmission Identification........................................................................................9
WARRANTY INFORMATION ..................................................................................12
Air Brake System.....................................................................................................12
FEDERAL AND CANADIAN EMISSION CONTROL SYSTEM WARRANTY
STATEMENT ..........................................................................................................13
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT..................15
FEDERAL, CANADIAN, AND CALIFORNIA EMISSION CONTROL
WARRANTY STATEMENT...................................................................................17
Emission Green House Gas Component Warranty (If Equipped) ...........................21
SERVICE LITERATURE ............................................................................................24
MACK Trucks Class 8 –Components Service Manual ...........................................24
Class 8 – Custom Collated Service Manual.............................................................24
Class 8 – Custom Collated Service Manual on CD .................................................24
CUSTOMER SERVICE ..............................................................................................25
Call 1-800-866-1177 for MACK Trucks OneCall™ ...............................................25
Questions and Complaints .......................................................................................25
Addresses .................................................................................................................26
Additional Assistance ..............................................................................................27
REPORTING SAFETY DEFECTS.............................................................................28
United States ............................................................................................................28
Canada......................................................................................................................28
Mexico .....................................................................................................................28
EVENT DATA RECORDING DEVICES...................................................................29
SAFETY INFORMATION ...........................................................................................30
SAFETY STATEMENT ..............................................................................................30
CERTIFICATION LABELS........................................................................................32
Safety Certification Label ........................................................................................32
ADVISORY LABELS .................................................................................................34
Advisory Label Locations (On Vehicle) ..................................................................35
Labels Found on Instrument Panel ..........................................................................43
TRUCK-TRACTOR CONSPICUITY.........................................................................46
CAB ENTRY/EXIT .....................................................................................................47
Three-Limb Contact.................................................................................................47
Driver Side ...............................................................................................................49
Passenger Side .........................................................................................................51
Deck Plate Access....................................................................................................53
SAFETY TIPS FOR COLD WEATHER OPERATION .............................................55
Driver Visibility .......................................................................................................55
Auxiliary Cab Heater ...............................................................................................56
Cab Door Seals and Key Locks ...............................................................................57
Outside Mirror Heater..............................................................................................57
Air Horn Snow Shield..............................................................................................58
Emergency Reflector Kit..........................................................................................58
Fire Extinguisher (Optional) ....................................................................................58
INSTRUMENTS AND CONTROLS ...........................................................................59
CAB INTERIOR..........................................................................................................59
Center Console (Day Cab Only) ..................................................................................60
Dead Pedal (Foot Rest) ................................................................................................61
INSTRUMENT PANEL ..............................................................................................62
Tell-Tales..................................................................................................................62
Panel Arrangement...................................................................................................62
INSTRUMENT PANEL GAUGE LAYOUT ..............................................................63
Panel A.....................................................................................................................64
Panel B .....................................................................................................................65
Panel C .....................................................................................................................67
Panel D.....................................................................................................................68
Moving Regeneration...............................................................................................83
Parked Regeneration ................................................................................................84
DPF INHIBIT ROAD SPEED LIMITING (RSL)...................................................86
Function of Optional Switches.................................................................................91
Radio ............................................................................................................................98
CAB CLIMATE CONTROL .......................................................................................98
Cab Auxiliary (Sleeper) HVAC Blower Switch ........................................................100
SLEEPER CLIMATE CONTROL ............................................................................101
LIGHT CONTROL PANEL ......................................................................................102
Ambient Floor Lighting .............................................................................................103
LOWER CONSOLE PANEL ....................................................................................104
STEERING COLUMN..............................................................................................105
Combination Starter and Electrical Switch............................................................105
Steering Wheel Adjustment ...................................................................................105
Self-Cancelling Turn Signal Lever ........................................................................106
Stalk Switch (If Equipped, Co-Pilot® Only) .........................................................108
FLOOR PEDALS ......................................................................................................110
MISCELLANEOUS CONTROLS ............................................................................ 111
Dome Light ............................................................................................................ 111
Interior Cab Lights (Sleeper Cab)..........................................................................112
Air Horn .................................................................................................................112
Fresh Air Vent ........................................................................................................113
Cab Air Filter .........................................................................................................114
Microphone ............................................................................................................115
Accessory Power Outlets .......................................................................................116
OPERATION................................................................................................................ 119
PRE-TRIP INSPECTION AND DAILY MAINTENANCE.....................................119
Pre-Trip Inspection Quick List ..............................................................................120
New Vehicle Break-In............................................................................................130
WINDSHIELD WASHER RESERVOIR ..................................................................133
HOOD OPERATION.................................................................................................134
Opening the Hood ..................................................................................................134
Closing the Hood ...................................................................................................136
Locking the Hood ..................................................................................................137
Closing and Locking Rear Fairing with Paddle Handles...........................................138
HOSE TENDERS ......................................................................................................139
DOORS ......................................................................................................................140
Standard Door Panel ..............................................................................................140
Power Door Panel (Optional).................................................................................141
Opening the Cab Door ...........................................................................................142
Locking the Cab Door............................................................................................142
Power Window Regulators ....................................................................................143
REMOTE KEYLESS ENTRY — (OPTIONAL)......................................................144
Transmitter Operations ..........................................................................................145
Battery Replacement..............................................................................................146
SEAT BELTS .............................................................................................................149
Seat Belt Operation ................................................................................................149
Fastening Seat Belt ................................................................................................149
Adjustable D-Ring Shoulder Belts (if equipped)...................................................151
Komfort® Latch System........................................................................................152
SLEEPER BUNK RESTRAINT ...............................................................................154
Upper Bunk (Optional) ..........................................................................................154
Bunk Restraint Operation ......................................................................................155
Bunk Restraint Maintenance..................................................................................155
SEAT ADJUSTMENT AND RECLINE (IF EQUIPPED)........................................156
HEATED SEAT (OPTIONAL)..................................................................................156
SWIVEL SEAT (OPTIONAL) ..................................................................................156
MACK Trucks ENGINE INFORMATION ...............................................................159
Precautions and Warnings......................................................................................159
Engine Model Designations...................................................................................160
CRUISE CONTROL OPERATION ..........................................................................161
Speed Control Switches .........................................................................................161
Setting Cruise Control ...........................................................................................162
Disengaging Cruise Control...................................................................................162
MACK Trucks POWERLEASH™ ENGINE BRAKE (IF EQUIPPED)..................163
MACK Trucks POWERLEASH™ ENGINE BRAKE ........................................164
Engine Brake Switch..............................................................................................165
How the Engine Brake is Activated.......................................................................166
Cruise Control with the MACK Trucks PowerLeash™ Engine Brake .................167
MACK Trucks PowerLeash™ Engine Brake without Cruise Control ..................169
Over Flat Terrain....................................................................................................170
Descending a Grade ...............................................................................................171
On Slippery Road Surfaces....................................................................................173
BRAKE .....................................................................................................................175
Air Brake System...................................................................................................175
Automatic Slack Adjusters ....................................................................................176
Parking Brake System............................................................................................177
Parking Brake ........................................................................................................177
Parking ...................................................................................................................177
Anti-Lock Brake System (ABS) ............................................................................178
Automatic Traction Control (ATC) (If Equipped) .................................................183
GOOD DRIVING HABITS.......................................................................................184
Weight Ratings.......................................................................................................184
Instruments.............................................................................................................184
Shutting Down the Engine .....................................................................................184
General Observation ..............................................................................................184
STARTING THE VEHICLE .....................................................................................185
General Information...............................................................................................185
Push Button Starters...............................................................................................185
Air Starters .............................................................................................................186
Engine Warm-Up ...................................................................................................189
Engine Idling..........................................................................................................189
Shutting Down the Engine .....................................................................................190
COLD WEATHER OPERATION .............................................................................192
Cold Weather Starting Tips....................................................................................192
Engine Block Heaters ............................................................................................193
Winterfronts ...........................................................................................................194
COUPLING A TRAILER..........................................................................................197
UNCOUPLING A TRAILER....................................................................................199
MOVING THE VEHICLE — GENERAL INFORMATION ...................................201
Braking...................................................................................................................201
Shifting...................................................................................................................201
Engine Temperature ...............................................................................................202
Clutch (If Equipped) ..............................................................................................203
POWER TAKE-OFF (PTO) OPERATION ...............................................................206
PTO Precautions ....................................................................................................206
PTO Classification .................................................................................................207
Side-Mounted PTO Locations ...............................................................................207
PTO Operating Procedures ....................................................................................207
TRANSMISSION SHIFTING INSTRUCTIONS.....................................................208
Shifting Instructions for Allison Automatic Transmissions ..................................208
MACK Trucks T306G Shifting Instructions .........................................................209
MACK Trucks TM308 Shifting Instructions.........................................................210
MACK Trucks TM308M Shifting Instructions .....................................................212
MACK Trucks TM309 Shifting Instructions.........................................................214
MACK Trucks TM309M Shifting Instructions .....................................................216
MACK Trucks T309, T309L and T309LR Shifting Instructions ..........................218
MACK Trucks T310 Shifting Instructions ............................................................222
MACK Trucks T310M, T310ME and T310MLR Shifting Instructions ...............224
MACK Trucks T313-T313L-T313LR Shifting Instructions .................................228
MACK Trucks T31321, T313L21 and T313LR21 Shifting Instructions ..............233
MACK Trucks T318, T318L and T318LR Shifting Instructions ..........................237
MACK Trucks T31821, T318L21 and T318LR21 Shifting Instructions ..............243
Precautions When Descending Grades If Vehicle is Equipped with Eaton
AutoShift Generation I and II ................................................................................249
AXLES.......................................................................................................................250
Rear Axles Other Than MACK Trucks .................................................................250
MACK Trucks Rear Axles.....................................................................................250
Engaging the Power Divider Lockout....................................................................251
MACK Trucks, EPA2010 Emissions Solution ..........................................................253
DIESEL PARTICULATE FILTERS (IF EQUIPPED) ..............................................253
Extended Idling and Aftertreatment System Conditioning ...................................256
Exhaust Aftertreatment System .................................................................................258
Safety Information .................................................................................................259
Exhaust Aftertreatment System Components and Operation ................................260
Aftertreatment Hydrocarbon Dosing System.........................................................260
Selective Catalytic Reduction (SCR) ....................................................................261
Diesel Exhaust Fluid (DEF)...................................................................................264
Aftertreatment Diesel Particulate Filter (DPF) ......................................................267
Aftertreatment Control Module (ACM).................................................................269
Exhaust Aftertreatment System ............................................................................270
Driver Warnings and On Board Diagnostics (OBD) .............................................275
On Board Diagnostics (OBD)................................................................................275
Instrument Cluster..................................................................................................276
Malfunction Indicator Lamp (MIL) .......................................................................278
Aftertreatment Driver Warning and Inducement ...................................................279
Aftertreatment DEF Tank Level - Driver Warning & Inducement........................279
Aftertreatment DEF Quality - Driver Warning & Inducement ..............................281
Aftertreatment Tampering - Driver Warning & Inducement .................................283
Misfilling Diesel or Aftertreatment DEF Tanks.....................................................285
MAINTENANCE AND LUBRICATION..................................................................286
MAINTENANCE INTRODUCTION .......................................................................286
TURBOCHARGER...................................................................................................287
CLEANING YOUR VEHICLE.................................................................................288
Exterior Washing ...................................................................................................288
Cab and Hood ........................................................................................................290
Chassis ...................................................................................................................290
Cab Interior ............................................................................................................290
Waxing ...................................................................................................................291
Polishing ................................................................................................................291
Winter Warnings ....................................................................................................291
TOWING ...................................................................................................................292
Towing with MACK Trucks Air (AL or MAXAIR® 40) Suspension (If
Equipped)...............................................................................................................294
ENGINE OIL LEVEL CHECK.................................................................................295
Checking Power Steering Fluid .............................................................................296
FUEL TANK..............................................................................................................297
Fuel Tank Cap ........................................................................................................297
FUELING ..................................................................................................................298
Use of Biodiesel for MACK Trucks US2010 Certified Products ..........................299
COOLING SYSTEM.................................................................................................300
Coolant Level Check..............................................................................................301
Draining the Cooling System.................................................................................301
Refilling the Cooling System .................................................................................301
Protecting the Cooling System ..............................................................................302
Cooling System Maintenance ................................................................................303
Accessory Drive Belt Routing ...............................................................................304
HEADLIGHTS ..........................................................................................................305
Bulb Replacement..................................................................................................305
LICENSE PLATE MOUNTING ...............................................................................305
WHEELS ...................................................................................................................306
Wheel Inspection ...................................................................................................306
Tires .......................................................................................................................307
BATTERY..................................................................................................................310
Jump-Starting Engine.............................................................................................311
ELECTRICAL ...........................................................................................................312
Circuit Breaker and Relay Panels ..........................................................................312
Electrical Grease ....................................................................................................314
Circuit Protection Charts........................................................................................315
Electrical Accessory Connection Points ................................................................318
Optional Body Builder Connectors (BBM-PK16 Option).....................................320
METRIC CONVERSIONS.........................................................................................323
METRIC CONVERSIONS .......................................................................................323
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.
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California
to cause cancer, birth defects and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
Battery posts, terminals and other related accessories contain lead and lead
compounds, chemical known to the State of California to cause cancer and other
reproductive harm.
Batteries also contain other chemicals known to the State of California to cause cancer.
Wash hands after handling.
Warning and Advisory Labels Advisory,
Danger, Warning and Caution labels are placed in various locations of the vehicle to
alert drivers and service technicians about situations that may lead to personal injury
or equipment damage. In the event that a label is damaged or missing the label must
be replaced. Contact your authorized MACK Trucks Truck dealer for assistance
regarding Warning and Advisory labels.
INTRODUCTION 1
TO THE OWNER
In Appreciation
Thank you for buying a MACK Trucks® vehicle. With proper care and
maintenance, your new MACK ® Pinnacle™ 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 ® Pinnacle™ 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
Trucks distributor if a question arises. Honest, personal service is standard
with every MACK Trucks sale.
CAUTION
MACK Trucks 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 hope that you will be happy with your new MACK ®
Pinnacle™ 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 ® Pinnacle™ CXU Series
Operator's Handbook. It covers all MACK® Pinnacle™ CXU models. Its
identification number is 22470031. 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 286. For further
information, refer to the Maintenance and Lubrication Manual Other important
information can be found in the Emission Control Systems for MACK Trucks Diesel
Engine Manual.
INTRODUCTION 3
THE VEHICLE
Basic Configuration
The MACK ® Pinnacle™ model features a conventionally styled, aerodynamic cab.
Vehicle Management and Control System
(V-MAC®)
The Vehicle Management and Control System (V-MAC) is an electronic
control system that manages engine and vehicle functions. In addition, the
DataMax™ portion of V-MAC monitors and stores a variety of information (i.e.,
maintenance schedules, overspeed logs, fault tables, trip summaries).
For a complete description of the V-MAC IV system, refer to the applicable
V-MAC® Operator's Guide, which is supplied with the vehicle.
Additional information concerning service, diagnostics, programming and
vendor equipment interface application is available from the MACK Trucks
Service Publications Department. Contact your local MACK Trucks 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 Trucks dealer for assistance.
4
INTRODUCTION
COMPONENT IDENTIFICATION
Locate the following serial numbers and write them in the boxes provided next
to each illustration.
INTRODUCTION 5
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 bottom right frame rail flange and
the top left rail flange. Note that the VIN location may vary if re-stamping of
the frame becomes necessary.
C0028939
C0028940
The VIN label is located on the inside door frame below the driver seat.
C0028941
6
INTRODUCTION
Engine Identification
On the MACK Trucks MP engines, the engine serial number is stamped on
the left side of the engine block, below the inlet manifold.
C0028943
INTRODUCTION 7
Engine Information Plate
In compliance with Federal and California emission requirements, an engine
information label is affixed to all MACK Trucks 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"
8
INTRODUCTION
CAUTION
To maintain compliance with emission
regulations, engine settings should not
be changed from those specified on the
engine information label.
Note: Both the U.S. EPA and California
Air Resources Board requires that each
engine be identified with the proper engine
label as shown above. Should this engine
label be defaced, destroyed, or removed
from the valve cover, it must be replaced
immediately. To order a replacement
label, please contact Specifications
or Parts Interpretations department at
1–800–888–9878, Option 2, who will
assist you in obtaining the correct label for
your engine.
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 left front corner of the hood on conventional models (CXU).
W2056289
Clean Idle Engine Label
INTRODUCTION 9
Transmission Identification
The MACK Trucks T300 Series transmission serial number is located on
the rear left side of the main case.
C0028947
The Allison RDS and HS transmission identification plate is located on the
rear right side of the main case, near the lower end.
C0028948
10
INTRODUCTION
All Eaton® Fuller® transmission identification plates are located on the
front left side of the main case.
C0028949
The MACK Trucks 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.
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.
INTRODUCTION 11
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
The MERITOR carrier assembly serial number is located on the left side of
the forward carrier, and the top of the rear carrier.
C0028954
12
INTRODUCTION
WARRANTY INFORMATION
This chassis is equipped with a US'10 emission compliant engine and an
exhaust aftertreatment system (Diesel Particulate Filter). Use of Ultra Low
Sulfur Diesel (ULSD) fuel and EO-O Premium Plus (or VDS-4) specification
high performance diesel engine oil is required in this vehicle.
Note: Use of improper or unapproved fuel or engine oil will void the engine and
aftertreatment system (Diesel Particulate Filter) warranty. 2007 emission engines
REQUIRE the use of EO-O Premium Plus (or VDS-4) specification high performance
diesel engine oil and Ultra Low Sulfur Diesel (ULSD) fuel.
Air Brake System
The MACK Trucks 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 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 Trucks 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 makes no representation as to conformity
with the Standards.
For complete warranty information, refer to the Pedigreed Protection Plan
provided with each vehicle.
INTRODUCTION 13
FEDERAL AND CANADIAN EMISSION CONTROL
SYSTEM WARRANTY STATEMENT
FEDERAL AND CANADIAN WARRANTY 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 Canadian
Environmental Protection Act, 1999.
MANUFACTURER’S WARRANTY COVERAGE
MACK Trucks warrants the Emission Control Systems on each new MACK Trucks
diesel engine in a new MACK Trucks 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), whichever occurs first, provided that
all 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 dealership, there will be no charge
for labor.
MACK Trucks’s obligation under this warranty is limited to the repair or replacement,
at MACK Trucks’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 and
provided that such part(s) were returned to MACK Trucks or its nearest authorized
Dealer within a reasonable period of time.
Note: For emission control systems information on engines other than MACK Trucks,
refer to the engine vendor’s publication
14
INTRODUCTION
TAMPERING WITH 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
3 Any person engaged in the business of repairing, servicing, selling, leasing, 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 Body Builders documentation.
INTRODUCTION 15
CALIFORNIA EMISSION CONTROL WARRANTY
STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and MACK Trucks Trucks (MACK Trucks) are
pleased to Explain the emission control system warranty on your 2014 / 2015 vehicle.
In California, new motor vehicle engines must be designed, built and equipped to meet
the State’s stringent anti-smog standards. MACK Trucks 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.
If an emission-related part of your engine is defective, the part will be repaired
or replaced by MACK Trucks. This is your emission control system DEFECTS
WARRANTY.
MANUFACTURER’S WARRANTY COVERAGE
(Applicable only to vehicles and/or engines certified for sale and registered in the
State of California)
MACK Trucks warrants the Emission Control Systems on each new MACK Trucks
diesel engine in a new MACK Trucks 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, whichever occurs first, provided all MACK Trucks
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 dealership, there will be no charge
for labor.
MACK Trucks’s obligation under this warranty is limited to the repair or replacement,
at MACK Trucks’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 and
provided that such part(s) were returned to MACK Trucks or its nearest authorized
Dealer within a reasonable period of time.
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 recommends that
you retain all receipts covering maintenance of your vehicle, but MACK Trucks
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 Trucks
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 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 MACK Trucks Trucks Warranty Activities P.O. Box 26259,
Greensboro, NC 27402, or the California Air Resources Board at 9480 Telstar Avenue,
El Monte, California 91731.
INTRODUCTION 17
FEDERAL, CANADIAN, AND CALIFORNIA
EMISSION CONTROL WARRANTY STATEMENT
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.
EMISSION CONTROL SYSTEM WARRANTY
The following engine components are covered by the supplemental emissions control
system warranty policy as required by the Code of Federal Regulations, California
Code of Regulations, and the regulations under the Canadian Environmental
Protection Act, 1999.
1 Engine Turbocharger Assembly
•
Variable Geometry Turbo (VGT)
Actuator
•
•
•
Aftertreatment Fuel Shutoff Valve
•
Aftertreatment DPF Intake
Temperature Sensor
•
Aftertreatment DPF Outlet
Temperature Sensor
•
Aftertreatment DPF Differential
Pressure Sensor
2 Charge Air Cooler (CAC)
3 Engine Control Module (ECM)
4 Injectors
5 EGR Cooler
6 EGR Valve and EGR Valve Control
7 EGR Venturi
8 Crankcase Breather (Does not include
Crankcase Pressure Sensor)
9 Crankcase Separator
10 Crankcase Tubing and Hoses before
Separator
11 Aftertreatment Wiring Harness (DPF)
12 Aftertreatment Wiring Harness (SCR)
•
•
•
•
Jumper to AHI Pressure Regulator
DEF Tank
13 Aftertreatment Control Module (ACM)
14 Aftertreatment Diesel Particulate Filter
(DPF) with Aftertreatment Diesel
Oxidation Catalyst (DOC)
•
Aftertreatment Doser
Engine Exhaust Gas Temperature
(EGT) Sensor
15 Sensors:
•
•
•
Crankshaft Position (CKP) Sensor
•
Intake Manifold Air
Temperature/Pressure Sensor
•
Exhaust Gas Recirculation (EGR)
Temperature Sensor
•
•
•
Aftertreatment Outlet NOx Sensor
ACM Power Supply
Heater NOx Care
Aftertreatment Fuel Pressure Sensor
•
Transmission Speed Sensor
Engine Coolant Temperature (ECT)
Sensor
Aftertreatment Intake NOx Sensor
Engine Exhaust Gas Recirculation
Differential Pressure Sensor
Ambient Air Temperature (AAT)
Sensor
16 SCR
18
INTRODUCTION
•
Aftertreatment Selective Catalytic
Reduction (SCR) Catalyst
•
Aftertreatment DEF Tank Heater
Valve
•
Aftertreatment Diesel Exhaust Fluid
(DEF) Pump
•
Aftertreatment DEF Tank
Temperature Sensor
•
Aftertreatment DEF Dosing
Absolute Pressure Sensor
Aftertreatment DEF Level Sensor
•
Aftertreatment DEF Return
Valve
•
•
•
•
•
•
•
Aftertreatment DEF Dosing Valve
Aftertreatment DEF Tank
Aftertreatment DEF Tank
Heater/Sender
Aftertreatment DEF Tank Heater
Aftertreatment DEF Heated Lines
Aftertreatment DEF Quality Sensor
17. Instrument Cluster (Repair of
Microprocessor)
18. Exhaust Gas Piping (from
Turbocharger to Aftertreatment
System)
INTRODUCTION 19
EMISSION CONTROL SYSTEM WARRANTY (CONT.)
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.
Note: In response to customer requests, MACK Trucks 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 Trucks Dealers, Sub-Dealers and Service Dealers Repairs
covered by the Emission Control Systems Warranty will be performed by any
authorized MACK Trucks repair facility with no charge for parts and labor (including
diagnosis), using MACK Trucks parts for any part of the emission control systems
covered by this warranty and found defective.
2. In an Emergency where an authorized MACK Trucks 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 Trucks will reimburse the owner
for such repairs that are covered under this warranty, including diagnosis, not to exceed
MACK Trucks’s suggested retail price for parts replaced and labor charges based on
MACK Trucks’s recommended time allowance and geographically appropriate hourly
labor rate. Replaced parts and paid invoices must be presented at a MACK Trucks
facility as a condition of reimbursement for emergency repairs performed elsewhere.
3. Repairs by Non-MACK Trucks 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 Trucks parts without invalidating the
warranty on other components, but the cost of such service or parts will not be covered
by MACK Trucks under its warranty.
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
20
INTRODUCTION
4. Use of Non-MACK Trucks Parts Use of replacement parts which are not the
equivalent of MACK Trucks parts may impair the effectiveness of emission control
systems. If other than MACK Trucks parts are used, the owner should obtain
assurances that such parts are warranted by their manufacturer to be the equivalent
of MACK Trucks parts in performance and durability. MACK Trucks assumes no
liability under this warranty with respect to parts other than MACK Trucks parts;
however, the use of non-MACK Trucks parts does not invalidate the warranty on other
components unless non-MACK Trucks 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 Trucks will
not deny a warranty claim solely because there is no record of maintenance; however,
MACK Trucks 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.
•
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 Trucks wishes to assure that the 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 Federal, Canadian,
or California Emission Control Systems Warranty, they should contact the nearest
MACK Trucks Regional Office for assistance. The address and telephone number for
each Regional Office are in the MACK Trucks Directory of Sales, Parts and Service
Centers. Owners in need of additional assistance or information concerning the
Emission Control Systems Warranty may also contact:
MACK Trucks
Warranty Activities
P.O. Box 26259
Greensboro, NC 27402
INTRODUCTION 21
Emission Green House Gas Component Warranty
(If Equipped)
MACK Trucks Trucks warrants certain individual greenhouse gas (GHG) components
and controls of each new MACK Trucks vehicle certified to the requirements of
Chapter 40 of the United States Code of Federal Regulations, Part 1037. MACK
Trucks GHG certified vehicles are warranted to be designed, built, and equipped so
they conform at the time of sale to the ultimate purchaser to the requirements of the
Part and to be free from defects in material and workmanship which, under normal
use and service, would cause the vehicle to fail to conform to the requirements of the
Part up to the periods specified, provided all MACK Trucks Trucks maintenance
and inspection requirements are followed. See your local authorized MACK Trucks
Trucks dealer for recommended maintenance and inspection procedures. All warranty
periods are calculated from the date in service of the vehicle. All coverage is 100%
for parts and labor subject to the qualifications, limitations and exclusions as noted.
LIMITATIONS AND EXCLUSIONS TO THIS WARRANTY APPEAR ON
THE FOLLOWING PAGES.
THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST
BE READ AND UNDERSTOOD.
This warranty applies to new MACK Trucks vehicles certified to the requirements of
40 CFR part 1037. MACK Trucks Trucks reserves the right to make any changes in
design, or make additions to or upon its products, without incurring any obligations to
install the same changes on vehicles previously built.
Emissions Components Coverage, Vehicle:
Not Covered by the Emissions Control System Warranty:
•
Malfunctions caused by misuse, improper adjustment, modification alteration,
tampering, disconnection, improper or inadequate maintenance and use of
improper diesel fuel or DEF.
•
Damage resulting from accident, act of nature or other events beyond the control of
MACK Trucks Trucks
•
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.
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.
22
INTRODUCTION
Tires, Drive and Steer Only: The first 24 months or 38624 km (24,000 miles) of
vehicle operation, whichever occurs first, and applying only to the first set of tires
on the vehicle when delivered to the ultimate purchaser. Subject to the terms and
conditions of the tire manufacturer’s warranty, excluding retreads. Emissions related
warranty coverage only, refer to the specific tire manufacturer’s warranty policy for
other term lengths.
Source of parts and repair A repair shop or person of the owner’s choosing may
maintain, replace, or repair emission control devices and systems.
Replacement of tires that are GHG certified The original equipment tires installed
on this vehicle at the factory were certified to the U.S. EPA Greenhouse Gas (GHG)
and NHTSA Fuel Efficiency regulations. Replacement of these tires should be with a
tire of equal or lower rolling resistance levels (TRRL or Crr). Please consult your tire
supplier(s) for appropriate replacement tires.
Maintaining a GHG certified tire In order to maintain the certified rolling resistance
of the tires which optimize fuel economy, the maintenance procedures provide by
the tire manufacturer must be followed.
All other Vehicle emission controls are warranted to 60 months or 160934 km
(100,000 miles), whichever occurs first.
Other vehicle components: 60 months or 160934 km (100,000 miles), whichever
occurs first.
Emission Control System Warranty
Vehicles sold for use in California must have the Operator’s Manual in the vehicle
which contains the California Emission System Warranty.
INTRODUCTION 23
Covered Emission Components List:
Qualifications and Limitations
Tires
Drive and Steer Only: The first 24 months
or 38624 km (24,000 miles) of vehicle
operation, whichever occurs first, and
applying only to the first set of tires on
the vehicle when delivered to the ultimate
purchaser.
Subject to the terms and conditions of the
tire manufacturer’s warranty, excluding
retreads.
Emissions related warranty coverage only,
refer to the specific tire manufacturer’s
warranty policy for other term lengths.
Exterior Components: Highway
Tractors Only
60 Months or 160934 km
(100,000 Miles), whichever occurs first.
Chassis Fairings
Ground Effect Extensions
Roof Deflectors
Cab Side Deflectors
Adjustable Roof Extensions
Side Deflector Extensions
Bumper Deflectors
A-pillar Deflectors
Air Conditioning Components: Only
those vehicles certified as “Tractors”
according to the requirements of
Chapter 40 of the Code of Federal
Regulations, Part 1037.
Hoses, Compressor to Condenser
Hoses, Condenser to Drier
Hoses, Drier to Climate Unit
Hoses, Climate Unit to Compressor
Hoses, Bunk Climate Unit
Receiver Drier, Spring Loaded, 12 cubic
in.
A/C Compressor
A/C Condenser
A/C Pressure Switches & Transducers
Main Climate Unit
Bunk Climate Unit
60 Months or 160934 km
(100,000 Miles), whichever occurs first.
24
INTRODUCTION
SERVICE LITERATURE
The MACK Trucks Service Publications department offers a variety of
service literature (including individual service manuals) that can be ordered
through any MACK Trucks dealer or on the MACK Trucks website at
www.macktrucks.com.
Note: MACK Trucks 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 Trucks standards.
MACK Trucks Class 8 –Components Service
Manual
This multi-binder set contains service information covering all MACK Trucks
components (i.e., engines, transmissions, front and rear axles, cabs, fuel
systems, electrical systems).
Note: If your vehicle contains a number of non-MACK Trucks (vendor) components,
the Class 8 – Custom Collated Service Manual might be more appropriate.
Class 8 – Custom Collated Service Manual
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 Trucks 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.
INTRODUCTION 25
CUSTOMER SERVICE
Call 1-800-866-1177 for MACK Trucks 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 Trucks 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 Trucks 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 Trucks 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 Trucks subsidiary or distributor, contact the regional service
manager at the nearest MACK Trucks 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.
26
INTRODUCTION
Addresses
The addresses, telephone and fax numbers of the MACK Trucks regional
offices are:
United States
Northeast Region – 2100 MACK Trucks Blvd., Mail: P.O. Box M, Allentown,
PA 18105-5000, TEL: (610) 966-8093, FAX: (610) 966-8005
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 Trucks Canada, 2100 Derry Road West, Suite 410,
Mississauga, ON L5N 0B3, TEL: (905) 366-3400, FAX: (905) 366-0165
Australia
MACK Trucks 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
2100 MACK Trucks Blvd., Mail: P.O. Box M, Allentown, PA 18105-5000, TEL:
(610) 709-3405, FAX: (610) 709-2323
INTRODUCTION 27
Additional Assistance
If additional assistance is required, MACK Trucks 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:
•
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
regional service office.
28
INTRODUCTION
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.
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.
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 Trucks 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 Trucks de Mexico by calling
011-52-55-50-81-68-50 or by writing to: MACK Trucks Trucks 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.
INTRODUCTION 29
EVENT DATA RECORDING DEVICES
Your MACK Trucks 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 Trucks 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 Trucks 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 Trucks
dealer or regional service office.
30
SAFETY INFORMATION
SAFETY STATEMENT
MACK Trucks 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 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.
SAFETY INFORMATION 31
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
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.
32
SAFETY INFORMATION
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 Trucks® 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.
SAFETY INFORMATION 33
Completed Vehicles
In addition to the label supplied by MACK Trucks 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 Trucks-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
34
SAFETY INFORMATION
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 Trucks® Pinnacle™
model chassis at the time of publication and are representative of what can be
typically found on a MACK Trucks® Pinnacle™. (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.
SAFETY INFORMATION 35
Advisory Label Locations (On Vehicle)
Labels Found on Chassis
C0028957
36
SAFETY INFORMATION
C0028958
SAFETY INFORMATION 37
C0028959
38
SAFETY INFORMATION
C0029012
SAFETY INFORMATION 39
C0029922
1. Right Side Frame Rail
2. Hood Prop
40
SAFETY INFORMATION
C0029014
SAFETY INFORMATION 41
Labels Found on Driver-Side Sun Visor
C0029015
42
SAFETY INFORMATION
C0029016
SAFETY INFORMATION 43
Labels Found on Instrument Panel
C0029017
Labels Found on Windshield
C0029018
Note: Label to be removed upon delivery to the end user.
44
SAFETY INFORMATION
R-134a Refrigerant Label
The servicing caution label 4MR3283M is located under the hood attached to the
receiver dryer bracket.
C0029019
Eaton Controlled Traction Differential Label
C0029020
SAFETY INFORMATION 45
Labels Found on Fuel Tank
C0029021
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.
C0029022
C0029923
46
SAFETY INFORMATION
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
2. Red and White Reflective Devices
(when not equipped with mudflaps
and brackets)
3. Red and White Reflective Devices
on Mudflaps or Hanger 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.
SAFETY INFORMATION 47
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.
48
SAFETY INFORMATION
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.
SAFETY INFORMATION 49
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 Trucks vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with both hands or
grab the outside handhold with one hand and grab the steering wheel with the other
hand. Then raise one foot to the bottom step. (See figure 1.)
2 Maintain a firm grip on the handhold and/or steering wheel and raise your other
foot to the top step. (See figure 2.)
3 While still gripping the handhold and/or steering wheel, raise one foot to the cab
floor. (See figure 3.)
4 Move one hand at a time to the steering wheel or 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 both hands gripping the steering wheel or cab interior, stand up and face the
inside of the cab. Move one foot to the top step. (See figure 4.)
2 Move one hand to the outside handhold and grip the steering wheel or cab interior
with the other hand. With one foot firmly on the top step, lower the other foot to
the bottom step. (See figure 3.)
3 Maintain a firm grip on the handhold and/or steering wheel, and keep one foot
firmly on the bottom step. Then lower the other foot to the ground. (See figure 2.)
4 With both hands firmly gripping the outside handhold, lower the other foot to the
ground. (See figure 1.)
50
SAFETY INFORMATION
C0029024
SAFETY INFORMATION 51
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
Trucks vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with both hands.
Then raise one foot to the bottom step. (See figure 1.)
2 Maintain a firm grip on the outside handhold with your left hand and grab the
inside handhold with your right hand. Then 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 right hand gripping the inside handhold and your left hand gripping
the cab interior, stand up and face the inside of the cab. Move one foot to the
top step. (See figure 4.)
2 While maintaining a firm grip on the inside handhold with your right hand, move
your left hand to the outside handhold. Then, lower the other foot to the bottom
step. (See figure 3.)
3 With a firm grip on both handholds and your foot planted securely on the bottom
step, lower the other foot to the ground. (See figure 2.)
4 Move your right hand to the outside handhold and lower the other foot to the
ground. (See figure 1.)
52
SAFETY INFORMATION
C0029025
SAFETY INFORMATION 53
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 top step. (See figure 2.)
3 Then with one foot planted firmly on the top step, move the other foot to the deck
plate. (See figure 3.)
4 Finally, move your other foot from the top 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 bottom step. (See figure 3.)
3 Then with one foot planted firmly on the bottom step, place the other foot on the
ground. (See figure 2.)
4 Finally, move foot from bottom step to the ground. (See figure 1.)
54
SAFETY INFORMATION
C0029130
SAFETY INFORMATION 55
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.
56
•
SAFETY INFORMATION
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.
Auxiliary Cab Heater
To ensure maximum in-cab comfort (even under severe cold weather
conditions) contact a MACK Trucks subsidiary or distributor for details
concerning auxiliary in-cab heaters (see figure below).
C0029131
SAFETY INFORMATION 57
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
58
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 59
CAB INTERIOR
C0029134
1. Instrument Panels
5. Hazard Switch
2. Cab Climate Control Panel
6. Turn Signal, Flash, HI/LO Beam,
Courtesy Flash and Flash to Pass
3. Foot Pedals
4. Tilt Control Pedal
60
INSTRUMENTS AND CONTROLS
Center Console (Day Cab Only)
The Center console has several features, a 12 V power supply located at the bottom of
the console, a 12 V light inside, map netting on the face, and the hard top that acts as a
writing surface with a maximum load capacity of 45 Kg (100 lb) . The console can be
removed and replaced with the current rear wall dispatch box.
W8073352
INSTRUMENTS AND CONTROLS 61
Dead Pedal (Foot Rest)
The dead pedal (foot rest) is located on the left hand side of the floor in the drivers
foot well.
W8073381
62
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 63
INSTRUMENT PANEL GAUGE LAYOUT
The instrument panel features a wrap-around dash with electronically
controlled "race type" gauges, meaning their needles point up when the truck
is running properly.
C0029135
64
INSTRUMENTS AND CONTROLS
Panel A
C0029136
1. Manifold Pressure Gauge (If
Equipped)
4. Exhaust Pyrometer (If Equipped)
2. Oil Pressure Gauge
5. Transmission Oil Temperature
Gauge (If Equipped)
3. Engine Oil Temperature Gauge
(Only with MACK Trucks Engine) 4.
Tilt Control Pedal
INSTRUMENTS AND CONTROLS 65
Panel B
W3030489
66
INSTRUMENTS AND CONTROLS
6. Integrated Temp-A-Start Indicator
(Amber) (If Equipped)
21. Engine Over Speed Indicator
(Red)
7. Wait to Start Indicator (Amber) (If
Equipped)
22. Trailer Anti-Lock Brake System
(ABS) Indicator (Amber)
8. Check Transmission Indicator
(Amber)
23. Power Take-Off Operating
Indicator (Green)
9. On Board Diagnostics Indicator
(Amber)
24. Cruise Control On Indicator
(Green)
10. Electronic Malfunction Indicator
(Amber)
25. Right Turn Signal Indicator
(Green)
11. High Beams Indicator (Blue)
26. Bendix Adaptive Cruise Control
(ACC) Indicator (Red)
12. Left Turn Signal Indicator (Green)
27. Reverse Indicator (Amber)
13. Parking Brake Indicator (Red)
28. Automatic Traction Control (ATC)
Indicator (Amber)
14. Engine Shutdown Indicator (Red)
29. Neutral Indicator (Amber)
15. Air Suspension Low Indicator
(Amber)
30. Fasten Seat Belt Warning
Indicator (Red)
16. Anti-Lock Brake System (ABS)
Indicator (Amber)
31. HEST Indicator (If Equipped)
17. Low Coolant Level Indicator
(Amber)
32. Fuel Gauge
18. Coolant Temperature Gauge
33. Mode Button (Basic Display Only)
19. Basic Display or Co-Pilot® (If
Equipped)
34. Speedometer
20. Water in Fuel Indicator (Amber)
(If Equipped)
35. Tachometer
INSTRUMENTS AND CONTROLS 67
Panel C
C0029138
36. Air Application or Air Suspension
Gauge (If Equipped)
39. Rear Rear Axle Oil Temperature
Gauge (If Equipped)
37. Hand-Control Brake Lever
40. Primary Air Pressure Gauge
38. Front Rear Axle Oil Temperature
Gauge (If Equipped)
41. Secondary Air Pressure Gauge
68
INSTRUMENTS AND CONTROLS
Panel D
W8075936
INSTRUMENTS AND CONTROLS 69
42. Wiper Speed/Delay/Wash Master
Switch
58. Optional Switch*
43. DPF Smart Switch (If Equipped)
59. Parking Brake Valve
44. Optional Switch*
60. Optional Switch*
45. Optional Switch*
61. Trailer Air Supply Valve
46. Optional Switch*
62. Optional Switch*
47. Optional Switch*
63. Optional Switch*
48. Optional Switch*
64. Optional Switch*
49. mDRIVE Automatic Transmission
Selector (If Equipped)
65. Optional Switch*
50. Air Filter Restriction Indicator (If
Equipped)
66. Optional Switch*
51. Accessory Power Outlet
67. Optional Switch*
52. Radio Box
68. Optional Switch*
53. AUX/USB Port
69. Optional Switch*
54. Cab Climate Control
70. Optional Switch*
55. Optional Switch*
71. Optional Switch*
56. Optional Switch*
72. Optional Switch*
57. Optional Switch*
73. Resume/Set Switch
74. Speed Control Switch
* The switches shown in parentheses are listed in their likely position on the
panel; however, they may be at other switch locations depending on the
customer's requirements. See “Function of Optional Switches”, page 91 for a
description of the optional switches, listed in alphabetical order.
70
INSTRUMENTS AND CONTROLS
1. Manifold Pressure Gauge (If Equipped) – Measures the charge air boost
pressure in the intake manifold.
2. Oil Pressure Gauge – Indicates engine oil pressure. The normal operating
oil pressure for a MACK Trucks 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).
3. Engine Oil Temperature Gauge (Only with MACK Trucks Engine) –
Indicates the temperature of the engine oil.
Note: At full-load operation, engine oil temperature can be approximately 250°F
on a sustained basis, and can intermittently reach temperatures between 250°F to
270°F. Sustained temperatures of 250°F and intermittent temperatures up to 270°F are
acceptable. However, if engine oil operation temperatures exceed 250°F more than
20% of the total engine operating time, and the oil has a minimum of 300 hours of
service, the oil must be changed. Otherwise, the normal mileage/time oil change
interval may be used. For the MACK Trucks recommended oil change intervals, refer
to the Maintenance and Lubrication Manual .
4. Exhaust Pyrometer (If Equipped) – Indicates the temperature of
exhaust gases (about 12 to 16 inches from the diesel particulate filter inlet
connections). This helps the operator select the proper gear for load and
grade conditions, thereby avoiding excessive exhaust temperatures.
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.
5. Transmission Oil Temperature Gauge (If Equipped) – Indicates
transmission oil temperature.
CAUTION
The maximum safe oil temperature for MACK Trucks 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 Trucks components.
INSTRUMENTS AND CONTROLS 71
6. Integrated Temp-A-Start (Amber) (If Equipped) – "Integrated Temp-A-Start"
saves fuel by reducing the amount of time spent idling to keep the vehicle's batteries
charged, the engine warm, or the cab and sleeper comfortable. Once the optional
'Integrated Temp-A-Start' feature is activated via a dash switch, the system will
automatically start and stop the truck engine. Safety overrides prevent the system
from activation if the transmission is in gear, the hood is up, or the parking brake is
released. Integrated Temp-A-Start voltage and temperature target settings are fully
programmable through either VCADS service support software, or, if enabled via
the Co-Pilot instrument cluster display.
7. Wait to Start (Amber) (If Equipped) – Indicates that the intake pre-heat is
enabled. Wait to start engine until light goes out.
8. Check Transmission Indicator (Amber) – Indicates that the transmission
oil temperature is above the warning limit.
9. On Board Diagnostics Indicator (Amber) – Indicates the need to access
the on board diagnostics port for information.
10. Electronic Malfunction Indicator (Amber) – Illuminates when V-MAC®
detects an electronic malfunction. Refer to the V-MAC® IV Operator's Guide.
The electronic malfunction lamp may turn on when operating the vehicle in
a bob-tail mode with the engine brake turned on and cruise control active.
Cruise control will become inoperative but can be reset by shutting off, then
restarting the engine. This condition can be corrected by resetting the "Service
Brake Fault Threshold with Engine Brake" function. Refer to V-MAC® IV
Customer Data Programming.
Note: Consult the appropriate vendor engine manual if your vehicle is not equipped
with a MACK Trucks engine.
11. High Beam Indicator (Blue) – Indicates that high beams are on.
12. Left Turn Signal Indicator (Green) – Flashes green when the left turn
signal is activated.
13. Parking Brake – Indicates that the parking brake is engaged.
72
INSTRUMENTS AND CONTROLS
14. 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 engine will be forced to idle. Once vehicle is stopped, the engine
will shut down. If the engine shutdown feature is disabled, the indicator will
function as a warning light but the engine will not shut down.
15. Air Suspension Low Indicator (Amber) (with air suspension only) –
Icon illuminated when air suspension lowered to warn driver not to drive in
this condition.
16. Anti-Lock Brake System (ABS) Indicator (Amber) – Indicates an ABS
malfunction. If the light turns on and stays on, a malfunction is indicated.
For additional information on operating an ABS-equipped vehicle, refer to
“Anti-Lock Brake System (ABS)”, page 178, of the OPERATION section.
Note: When an ABS malfunction is detected, anti-lock braking in the affected
wheel(s) will be disabled and normal braking will return; the other wheels will retain
anti-lock braking. Operate the vehicle normally and have the ABS system serviced
to correct the fault.
17. Low Coolant Level Indicator (Amber) – Illuminates when the coolant
level in the coolant surge tank is below the specified level. Stop and add
coolant. Use typical warnings, etc., for filling coolant.
18. Coolant Temperature Gauge – Indicates the temperature of the engine
coolant. The normal operating temperature for MACK Trucks 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).
INSTRUMENTS AND CONTROLS 73
19. Basic Display or Co-Pilot® (If Equipped)
BASIC DISPLAY
The Basic Display is an in-dash computer that allows the vehicle operator to
monitor a minimum amount of information supplied by the V-MAC IV electronic
control system. The operator presses a push button located directly below the
driver information display to retrieve information.
Note: The Basic Display does not use a stalk switch, which is only available with
the Co-Pilot® display.
The following information is available in the Basic Display:
• Current Conditions
C0029140
74
INSTRUMENTS AND CONTROLS
• Trip Information
C0029141
Diagnostics
INSTRUMENTS AND CONTROLS 75
Diagnostics
W3036575
W3036576
W3036583
W3036584
76
INSTRUMENTS AND CONTROLS
OR
CO-PILOT® (If Equipped)
Co-Pilot® is an in-dash computer that allows the vehicle operator to monitor
information supplied by the V-MAC® electronic control system. The Co-Pilot®
enhances the functions of V-MAC® by entering requested information with the
stalk switch. The Co-Pilot® is very "user friendly" and prompts the operator
with messages on the display screen. For more information on how to use the
Co-Pilot®, please consult the V-MAC® IV Vehicle Management and Control
with Co-Pilot® Display Operator's Guide.
GuardDog™ (Optional; Must be Enabled)
GuardDog™, an active maintenance monitoring system, uses sensor readings
to show the status of routine maintenance requirements. If the vehicle is
equipped with the GuardDog™ system, Co-Pilot® will display GuardDog™
related maintenance items under the following conditions:
• When the vehicle is started
C0029143
• If no vehicle data is available from the system the following screen displays.
W1030401
INSTRUMENTS AND CONTROLS 77
• If the engine is started to soon for the system to complete a proper engine
level reading the following screen displays.
W1030391
• During driving as individual maintenance items become due, the following
screen displays.
W1030395
78
INSTRUMENTS AND CONTROLS
• During driving if no maintenance is due, the following screen displays.
W1030406
• Manually through the GuardDog™ Status screen
W3030649
For more information on GuardDog™, Co-Pilot® display and Basic Display,
please refer to the V-MAC® IV Operator's Guide.
20. Water in Fuel Indicator (Amber) (If Equipped) – Illuminates when water
accumulates in the primary fuel filter sediment bowl. Stop the engine and
drain the fuel from the sediment bowl.
21. Engine Over Speed Indicator (Red) – Illuminates when maximum
engine RPM is exceeded.
22. Trailer Anti-Lock Brake System (ABS) Indicator (Amber) – Indicates an
ABS malfunction. If the light turns on and stays on, a malfunction is indicated.
For additional information on operating an ABS-equipped vehicle, refer to
“Anti-Lock Brake System (ABS)”, page 178, of the OPERATION section.
INSTRUMENTS AND CONTROLS 79
Note: When an ABS malfunction is detected, anti-lock braking in the affected
wheel(s) will be disabled and normal braking will return; the other wheels will retain
anti-lock braking. Operate the vehicle normally and have the ABS system serviced
to correct the fault.
23. Power Take-Off Operating Indicator (Green) – Indicates PTO operation.
24. Cruise Control Indicator (Green) – Indicates that cruise control is
engaged.
25. Right Turn Signal Indicator (Green) – Flashes green when turn signal
is activated.
26. Bendix Adaptive Cruise Control (ACC) Indicator (Red)–Illuminates
when the Bendix ACC engages.
27. Reverse Indicator (Amber) – Indicates that the transmission is in
Reverse.
28. Automatic Traction Control (ATC) Indicator (Amber) – Indicates that
ATC is operating and will flash when in deep mud and snow mode.
29. Neutral Indicator (Amber) – Indicates that the transmission is in Neutral.
30. Fasten Seat Belt Warning Indicator (If Equipped) (Red)
31. High Exhaust System Temperature (HEST) Icon – 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 an automatic regeneration while the vehicle is moving, the HEST
indicator will only illuminate during regeneration 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
32. Fuel Gauge – Registers the fuel level in the supply tank(s).
80
INSTRUMENTS AND CONTROLS
33. Mode Button (Basic Display Only) – This push button is located directly
below the Basic Display. The push button is used to access, navigate, view
and change information available in the Basic Display. Simply press and hold
the push button in for a moment to navigate through the screens. A long press
of the push button is used to clear trip data or inactive fault codes.
For more information on this button, please refer to the V-MAC® IV Operator's
Guide.
34. Speedometer — Indicates road speed in miles and/or kilometers per hour.
35. 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.
36. Air Application Gauge (If Equipped) – Indicates the air pressure being
delivered to the service brake chambers in the tractor (and trailer, if equipped);
OR
Air Suspension Gauge (If Equipped) – Indicates the air pressure being
delivered to the air suspension system (100 psi range).
37. Hand-Control Brake Lever – Pull down to activate the trailer brakes, or
the rear axle brakes in the case of a platform truck.
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.
38. Front Rear Axle and 39. Rear Rear Axle Oil Temperature Gauges (If
Equipped) – Indicate rear axle oil temperature.
CAUTION
The maximum safe oil temperature for MACK Trucks rear axles is 121°C (250°F).
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 Trucks components.
INSTRUMENTS AND CONTROLS 81
40. Primary and 41. Secondary 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.
42. Wiper Speed/Delay/Wash Master Switch
• Depress top of the rocker switch to activate windshield washer
• Toggle switch in top position turns wipers on HIGH
• Toggle switch in second position from top turns wipers on LOW
• Toggle switch in the center position activates intermittent wipers. Pressing
the switch down slows the speed of the wipers
• Toggle switch in the lowest position turns wipers OFF
C0029147
Wiper Speed/Delay/Wash Master Switch
1. Press to Wash
4. Intermittent
2. Hi
5. Off
3. Lo
82
INSTRUMENTS AND CONTROLS
43. DPF Smart Switch (If Equipped) – This is a three-position switch where
the middle position is neutral.
C0029148
DPF Smart Switch
1. Upper Position – Regeneration
Position
2. Middle Position – Neutral Position
3. Down Position – Inhibit Position
INSTRUMENTS AND CONTROLS 83
Moving Regeneration
"Moving" regeneration occurs while the vehicle is being driven and can
be 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: The vehicle operator should try to maintain vehicle speed during the
regeneration process. If the vehicle must be stopped (at a traffic light for example),
allow the vehicle to idle and do not apply the park brake. Applying the park brake will
disrupt and end a regeneration that started while the vehicle was being driven.
Please refer to the instructions below on how to use the DPF Smart switch
during a regeneration that occurs while the vehicle is being driven.
Moving (Automatic) Regeneration
1 When the icons on the DPF Smart switch light up, maintain vehicle speed if
possible.
2 During regeneration, the icons on the switch will shut off.
3 Regeneration will take between 20 and 30 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.).
Moving (Manual) 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 20 and 30 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.).
Depending on the vehicle's set up, it may be possible to perform a parked
regeneration if necessary.
84
INSTRUMENTS AND CONTROLS
Parked Regeneration
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. For catalyzed exhaust aftertreatment systems, the engine speed may ramp
as high as 1,100 rpm. For non-catalyzed exhaust aftertreatment systems, the
engine will continue to idle during the regeneration.
5. Regeneration will take between 20 and 30 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.).
INSTRUMENTS AND CONTROLS 85
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 too many times, the vehicle must be taken to a MACK Trucks 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.
86
INSTRUMENTS AND CONTROLS
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:
The following label is located on the driver-side sun visor which provides
additional instructions on the exhaust aftertreatment system.
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.
INSTRUMENTS AND CONTROLS 87
The following label is located on the driver-side sun visor which provides
additional instructions on the exhaust aftertreatment system.
C0029149
For more information on the DPF Smart Switch, please refer to the V-MAC®
IV Operator's Guide.
88
INSTRUMENTS AND CONTROLS
44. Optional Switch – Refer to “Function of Optional Switches”, page 91.
45. Optional Switch – Refer to “Function of Optional Switches”, page 91.
46. Optional Switch – Refer to “Function of Optional Switches”, page 91.
47. Optional Switch – Refer to “Function of Optional Switches”, page 91.
48. Optional Switch – Refer to “Function of Optional Switches”, page 91.
49. Storage Box or Automatic Transmission Selector (If Equipped) – See
your Automatic Transmission Operator's Manual supplied with this vehicle.
50. 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.
51. Accessory Power Outlet – See instructions under Accessory Power
Outlets listed in the Instrument and Controls Section of this manual.
52. Radio Box – For radio instruction refer to vendor supplied information.
53. AUX/USB Port
• AUX Port – Use this port to have audio from any unit played over the vehicle
audio system.
• USB Port – Insert a memory stick, with MP3 music downloaded, and
the music will be heard from the vehicle audio system. The music can be
controlled with the radio or steering wheel features (if equipped). You can also
use this port with the USB style MP3 players.
• AUX and USB together – Use both ports together for IPOD control. A special
cable is required for this function. Once the IPOD is connected, it will display a
MACK Trucks logo on the IPOD screen and will let you know that the IPOD can
now be controlled by the radio or steering wheel features (if equipped). At this
point, the IPOD can be stored out of sight. This port will also charge the IPOD.
For more information on the AUX/USB port, for radio instruction refer to
vendor supplied information.
54. Cab Climate Control – See instructions under Cab Climate Control listed
in the Instrument and Controls Section of this manual.
55. Optional Switch – Refer to “Function of Optional Switches”, page 91.
56. Optional Switch – Refer to “Function of Optional Switches”, page 91.
57. Optional Switch – Refer to “Function of Optional Switches”, page 91.
58. Optional Switch – Refer to “Function of Optional Switches”, page 91.
59. Parking Brake Valve – Yellow diamond-shaped knob. Pull to apply. Push
to release. Applies tractor parking brakes and trailer brakes, if equipped.
60. Optional Switch – Refer to “Function of Optional Switches”, page 91.
INSTRUMENTS AND CONTROLS 89
61. Trailer Air Supply Valve – Red octagonally-shaped knob. Pull to apply
trailer emergency brakes. Push to pressurize the trailer air reservoir, releasing
the trailer emergency brakes.
Note: The trailer air supply valve should NOT be used for parking.
62. Optional Switch – Refer to “Function of Optional Switches”, page 91.
63. Optional Switch – Refer to “Function of Optional Switches”, page 91.
64. Optional Switch – Refer to “Function of Optional Switches”, page 91.
65. Optional Switch – Refer to “Function of Optional Switches”, page 91.
66. Optional Switch – Refer to “Function of Optional Switches”, page 91.
67. Optional Switch – Refer to “Function of Optional Switches”, page 91.
68. Optional Switch – Refer to “Function of Optional Switches”, page 91.
69. Optional Switch – Refer to “Function of Optional Switches”, page 91.
70. Optional Switch – Refer to “Function of Optional Switches”, page 91.
71. Optional Switch – Refer to “Function of Optional Switches”, page 91.
72. Optional Switch – Refer to “Function of Optional Switches”, page 91.
73. Resume/Set Switch – This is a V-MAC® switch; refer to the V-MAC® IV
Operator's Guide for more information.
C0029150
90
INSTRUMENTS AND CONTROLS
74. Speed Control Switch – This is a V-MAC® switch; refer to the V-MAC®
IV Operator's Guide for more information.
C0029211
INSTRUMENTS AND CONTROLS 91
Function of Optional Switches
C0029212
Optional Switches
1. Accessory Battery Power Switch
9. Fan Control Manual Override
Switch
2. Accessory Ignition Power Switch
10. 5th Wheel Slide Switch
3. Air Suspension Control Switch
11. Inside/Outside Air Switch
4. Automatic Traction Control Switch
12. Load Light Switch
5. Body Warning Lamp
13. Mirror Defrost Switch
6. Daytime Running Lights Override
Switch
14. Motorized-Mirror Joy Stick
7. Engine Brake Switch
15. Power Divider Lockout Switch
8. Shutdown Override Switch
16. Power Take-Off Control Switch
92
INSTRUMENTS AND CONTROLS
C0029213
Optional Switches
1. Push Axle Up/Down Switch
7. Spin Light Switch
2. Push Axle Up/Down Switches
8. Strobe Switch
3. QUAL COMM Panic Button
9. Telma Retarder Lamp
4. Right-Hand Only Door Lock Switch
10. Vent Fan Switch
5. Right-Hand Only Window Lift
Switch
11. Windshield Defrost Switch
6. Snow Plow Lamps Switch
INSTRUMENTS AND CONTROLS 93
The following optional switches, listed in alphabetical order, may appear on
Panel D, shown on “Panel D”, page 68.
• Accessory Switch (Battery Power) – This switch may be used to power
optional accessory equipment that requires battery voltage, with the key
switch turned OFF.
• Accessory Switch (Ignition Power) – This switch may be used to power
optional accessory equipment that requires ignition voltage, with the key
switch turned ON.
• 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.
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.
Note: Engine speed and road speed will automatically be limited if the vehicle is
moved with the air bags exhausted.
For information concerning trailer coupling and uncoupling, refer to the
OPERATION section of this manual.
94
INSTRUMENTS AND CONTROLS
• 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 183 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.
• Body Warning Lamp – The Body Lamp illuminates a RED warning icon
on the "D" panel to alert the driver of a body function as defined by the
bodybuilder. As an example, the body warning lamp will illuminate to alert the
driver that the dump body is not fully down.
C0029214
• Daytime Running Lights (DRL) Override Switch – Daytime Running
Lights (DRL) come standard on all MACK Trucks vehicles and can be
optioned with or without an override switch. When the DRL override switch
has been specified, different conditions can be selected that cause the DRL to
automatically activate, DRL can be automatically turned on when the parking
brake is released, the engine is running or both. Only one of these choices
may be selected. Using DRL will illuminate the low beam headlamp bulbs at
a slightly reduced intensity. The DRL function will monitor high beams as
well. If the high beams are activated, the DRL will be temporarily turned off
until high beam use ceases.
INSTRUMENTS AND CONTROLS 95
Daytime running lights offer additional safety when driving in low light
conditions when the operator may not normally turn the headlights on. Having
headlights on at all times makes the vehicle easier to spot in bad weather,
dusk or shade or when there is glare. DRL offers the ability for drivers to give
a courtesy flash as a signal when it is safe to merge into another lane on the
highway. Turning DRL off temporarily for slowly rolling through weigh stations
or when waiting in line to receive bill and weighing tickets is convenient.
When the operator presses the DRL override switch, the headlamps will go out
if below the DRL speed threshold and flash if above the DRL speed threshold
for a designated period of time (customer programmable in VCADS). It is also
possible to toggle the headlamps back on if necessary.
• Engine Brake Switch – Used to activate the engine brake. Refer to the
OPERATION section in this handbook for more information.
• Fan Control Manual Override Switch – Allows the operator to manually
control the engine cooling fan.
• 5th Wheel Slide Switch – Locks and releases a sliding 5th wheel using air
pressure; this allows the 5th wheel to be properly positioned. The indicator
lamp will illuminate when the 5th wheel is unlocked. Prior to model year 2001,
it was necessary to use the trailer Hand Brake Control Lever to activate the
5th wheel slide function. This feature has been changed to make the air slide
switch independent of the hand brake control, thereby preventing unexpected
5th wheel slide.
• Inside/Outside Air Switch – Allows the operator to choose whether outside
air or "under the hood" air is fed into the air cleaner.
• Load Light Switch – Push top of the switch in to turn light on. Push bottom
of switch to turn light off.
• Mirror Defrost – Push the top in to activate mirror defrost.
96
INSTRUMENTS AND CONTROLS
• Motorized-Mirror Joy Stick – This control is designed like a "joy stick."
ROTATE the stick to the right to control the right mirror. ROTATE the stick to
the left to control the left mirror. PUSH the stick up, down, left or right, as
indicated, to correctly position the selected mirror.
C0029215
• 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.
• Push Axle Up/Down Switch — The operator controls the raise and lower
functions with the instrument panel-mounted auxiliary axle switch(es), and
axle loading is controlled by the air regulators which are located inside the cab
between the driver and the rider seats. There is one regulator for each axle.
Note: To prevent frame damage, the auxiliary axle(s) will automatically raise when
the transmission is shifted into reverse.
C0029216
1. Air Pressure Gauge
2. Air Pressure Regulator
INSTRUMENTS AND CONTROLS 97
• QUAL COMM Panic Button — If your vehicle is equipped with this option,
refer to the QUAL COMM literature provided with the vehicle.
• Right-Hand Only Door Lock — Push the top in to lock the right-hand door.
• Right-Hand Only Window Lift — Push the top of the button to raise the
right-hand window. Push bottom of button to lower right-hand window.
• Shutdown Override Switch — Pressing this switch shortly after the vehicle
sounds the engine shutdown alarm, allows 30 additional seconds of operation.
The process can be repeated several times to safely park the vehicle.
CAUTION
Continuously overriding the shutdown system may result in severe engine damage.
• Snow Plow Lamps Switch — Push the top of the button to turn on the
snow plow lamps if equipped.
• Spin Light Switch — Push the top of the button to activate the rotating
beacon light. Push the bottom to turn light off.
• Strobe Switch — Push the top of the button to turn the strobe light on. Push
the bottom of the button to turn light off.
• Telma Rear Axle Mounted Retarder Indicator Lamp (If Equipped) —
The Telma does not have a disable switch. It is always on and will operate
at 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
• Vent Fan Switch — Push button up to turn vent fan on. Push button down to
turn vent fan off.
• Windshield Defrost Switch — Push button up and release to defrost front
windshield.
98
INSTRUMENTS AND CONTROLS
Radio
For radio instruction refer to vendor supplied information.
CAB CLIMATE CONTROL
C0029218
1. Blower Control Knob
4. Fresh/Recirculation Button
2. Temperature Control Knob
5. A/C ON/OFF Button
3. Mode Knob
1. Blower Control Knob — This knob controls fan speed from OFF to 4
(highest speed).
2. Temperature Control Knob — Controls the temperature of the air in the
cab from COOL (far left) to HOT (far right).
3. Mode Selection Knob — Controls the direction of air flow around the
cab as follows:
INSTRUMENTS AND CONTROLS 99
C0029219
1. Directs airflow through the dash
panel air vents only.
4. Directs airflow through the floor
vents and the windshield for defrosting
and/or defogging.
2. Directs airflow through both
the dash panel and floor air vents
(bi-level).
5. Directs airflow only to the
windshield for defrosting and/or
defogging.
3. Directs airflow through the floor
vents only.
Note: The Mode Selection knob can be rotated to any position (see above). This
allows the operator to select the desired amount of blend between the positions.
4. Fresh/Recirculation Switch or Button — Selects the cab intake air
between fresh air (from outside the cab) and recirculated air (inside the cab).
Note: For maximum air conditioner performance, select recirculated air.
5. Air Conditioner ON/OFF Switch or Button — Activates the air
conditioning system.
Note: When using the sleeper air conditioner, this switch must be turned ON.
100
INSTRUMENTS AND CONTROLS
Cab Auxiliary (Sleeper) HVAC Blower Switch
The cab auxiliary (Sleeper) HVAC blower switch is located in panel D of the dash
(refer to instrument and controls) in operator’s handbook. The switch is in the rocker
panel bay above the engine cover. In order for the rear sleeper controls to operate, the
cab auxiliary (Sleeper) HVAC blower switch must be turned on at the rocker panel.
The function is to interrupt the auxiliary HVAC blower circuit. This allows the sleeper
to be pre-warmed or pre-cooled from the cab. So, for example, a driver may preset
the sleeper HVAC to activate A/C at medium blower speed. Then he can interrupt
the circuit from the driver seat. About 15 min before he wants to pull over to rest,
he can activate the sleeper Aux HVAC circuit to pre-cool the sleeper. This switch
is standard with all sleepers with aux HVAC (MACK Trucks 60” & 70” sleepers).
The switch icon is shown below.
W8074020
INSTRUMENTS AND CONTROLS 101
SLEEPER CLIMATE CONTROL
C0029220
1. Fan Control Knob
3. Temperature Control Knob
2. Mode Selection Knob
1. Fan Control Knob — This is a three position knob to control the amount
of air delivered through the sleeper box air vents.
2. Mode Selection Knob — Allows the operator to choose between OFF,
HEAT or A/C.
3. Temperature Control Knob — Controls the temperature of the air in the
sleeper from COOL (far left) to HOT (far right).
Note: When the sleeper mode selection knob is in the OFF position, warm air flows
out the sleeper box air vents. As a result, the sleeper may become quite warm and
uncomfortable on hot summer days.
To use the sleeper box air conditioner, make sure that the Cab air conditioning
unit is activated and the cab fan control switch must be ON (any speed). Then,
on the sleeper climate control panel, move the mode selection knob to the A/C
position and turn the temperature control knob to COOL.
If the sleeper box becomes too cold and you want to regulate the temperature,
the cab air conditioning unit must be activated and the fan switch turned ON to
any speed. Then, turn the sleeper mode selection knob to HEAT, then use the
temperature control knob to adjust to the desired temperature.
102
INSTRUMENTS AND CONTROLS
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).
C0029221
Light Control Panel
1. Light Control Knob/Pull for Fog
3. Hook-Up Lamps or Perimeter
Lighting (If Equipped)
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, move the panel dimmer switch back
and forth.
To turn on the hook-up lamps or perimeter lighting (if equipped), push the
bottom switch to the right.
INSTRUMENTS AND CONTROLS 103
Ambient Floor Lighting
The ambient lighting is in 3 locations, driver foot well, and the center and passenger
side of the console. The switch will be located on the lower panel below the main
light switch. The switch is a 3 position switch, with the positions listed below:
1st. “OFF” position
2nd. Driver foot well only
3rd. Entire cab floor area
The lighting color for the ambient lighting is soft red to avoid affecting night vision.
W2073628
1 Switch
2 Ambient Lamps
104
INSTRUMENTS AND CONTROLS
LOWER CONSOLE PANEL
The lower console panel is located under the Cab Climate Control area of
the middle dash.
C0029222
1. Cigar Lighter
3. Accessory Power Outlet
2. Ashtray
4. Cup Holder
INSTRUMENTS AND CONTROLS 105
STEERING COLUMN
Combination Starter and Electrical Switch
The lower console panel is located under the Cab Climate Control area of
the middle dash.
C0029223
This switch starts the engine (turn the switch clockwise) and activates the
accessory relay (turn the switch counterclockwise). When the switch is turned
ON (in a clockwise direction), a warning buzzer sounds if air system pressure
is below 448 ± 34 kPa (65 ± 5 psi) or if there is low oil pressure. The buzzer
shuts off as soon as sufficient air/oil pressure is restored.
Steering Wheel Adjustment
WARNING
Adjust the steering wheel position BEFORE attempting to move the vehicle
to avoid losing control of the vehicle.
Adjusting (Tilt and Telescope)
Push down on the foot pedal located at the left kick panel to adjust the wheel
to any position within a pre-defined range. Note that you must continue to hold
the pedal down while adjusting. When the adjustment is complete, release
the pedal.
106
INSTRUMENTS AND CONTROLS
Self-Cancelling Turn Signal Lever
The turn signal lever is located on the steering column and is self-cancelling. It
performs a number of functions, including switching from high and low beams,
turn signal switch and the hazard switch. The turn signal switch can be used
for courtesy flashing of marker lights and for the flashing of high beams.
W3075524
1. Clearance Flash
3. Pull for Hazard (Red)
2. Headlamp Flash
4. Cluster Display Control
INSTRUMENTS AND CONTROLS 107
C0029225
1. Handle in Right Turn Position and
Cancel Position of Hazard Warning
4. Push for Courtesy Flashing of High
Beams
2. Handle in Left Turn Position and
Cancel Position of Hazard Warning
5. Push for Courtesy Flashing of
Marker Lights (Daylight or Dark)
3. Pull for Warning Hazard Position
6. Lift Handle for Headlight Dimmer
108
INSTRUMENTS AND CONTROLS
Stalk Switch (If Equipped, Co-Pilot® Only)
The stalk switch (Co-Pilot® only) is located on the right side of the steering
column and contains three depressible buttons: ESC, Enter (↵ ) and Up
& Down. The stalk switch is used to access, navigate, view and change
information available in the driver information display (Co-Pilot® display).
The following illustration shows the stalk switch.
C0029226
1. ESC (Escape)
2. ↵ (Enter)
3. Up & Down
INSTRUMENTS AND CONTROLS 109
Navigation of Co-Pilot® Menu
ESC BUTTON
The ESC (Escape) button on the stalk switch takes the Co-Pilot® back to the
previous screen or level in the menu.
Note: The ESC button does not function at Start Up or when the vehicle is moving.
The ESC button is used only when the vehicle is stationary.
↵ ) BUTTON
ENTER (↵
The Enter (↵ ) button on the stalk switch selects the highlighted menu items
during menu selection. During Start Up and when moving the vehicle, the
Enter(↵ ) button is also used to confirm or acknowledge a pop-up screen.
Sometimes, the Enter(↵ ) button takes the Co-Pilot® back to the previous
screen.
UP & DOWN BUTTONS
The Up & Down buttons at the end of the stalk switch allow the user to
highlight the various available menu items. Sometimes, these buttons are
used to enter information into the displays.
• Up Button — Once at the top of the menu items that can be selected,
pressing the Up button will take the display to the last item in the menu.
For more information on Co-Pilot® display, please refer to the V-MAC® IV
Operator's Guide.
110
INSTRUMENTS AND CONTROLS
FLOOR PEDALS
C0029227
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.
4. Steering Wheel Adjustment Pedal — Push down on the foot pedal to
tilt the wheel to any position between fully tilted up to fully tilted down. You
must hold the pedal down while adjusting. When the adjustment is complete,
release the pedal.
INSTRUMENTS AND CONTROLS 111
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.
112
INSTRUMENTS AND CONTROLS
Interior Cab Lights (Sleeper Cab)
Various interior cab lights are activated using the rocker switches located
in the headliner.
C0029231
Driver Side
1. Map Light Switch Activates the
map lights (which are located in the
headliner, to the left of sun visor).
3. Sleeper Light Switch Activates the
sleeper ceiling lights.
2. Dome Light Switch Activates the
dome lights.
Air Horn
C0029232
The air horn(s), if equipped, is activated by pulling down on the cord that is
located above the driver near the overhead console.
INSTRUMENTS AND CONTROLS 113
Fresh Air Vent
C0029233
An air vent is provided to circulate outside air to the cab interior. Move the
vent lever to the left or right to open the vent. Move the lever to the left to
close the vent.
On chassis equipped with a sleeper cab, there is an air vent located on either
side of the bunk. Pull handle to the left or to the right (depending on what side
of the cab you are on) to open the vent.
C0029234
114
INSTRUMENTS AND CONTROLS
Cab Air Filter
W8056454
To provide comfortable and clean fresh air in the cab, the heating and air conditioning
system is designed with a replaceable filter.
Under normal operating conditions the filter should be replaced every 6 months to
ensure the efficiency of the heating and air conditioning system. Failure to replace
the filter may cause damage to heater/AC components.
Note: Dusty conditions may require more frequent replacement.
INSTRUMENTS AND CONTROLS 115
Microphone
C0029235
Microphone
The microphone is located above the driver in the headliner. It is available on
the Mid-Level radio with Blue Tooth/Hands free option. This is what is used to
talk into when the phone is connected to the truck. For more information on
the microphone, for radio instruction refer to vendor supplied information.
116
INSTRUMENTS AND CONTROLS
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.
C0029236
C0029238
INSTRUMENTS AND CONTROLS 117
On chassis equipped with a sleeper cab, there are also additional power
outlets located above the bunk.
C0029239
CAUTION
Maximum amperage for all power receptacles in cab is 20 amps. Do NOT exceed
maximum amperage as equipment damage may result.
CB Radio Power Jack (+) Located in Headliner on Sleeper Cab; on
Dashboard in Day Cab (Red)
This is a 12-volt, switched battery connection. It is used to power the vehicle's
CB radio. It is protected by a 15-amp circuit breaker and supplies power when
the key is in the ACCESSORY position or ON position.
CB Radio Power Jack (-) Located in Headliner on Sleeper Cab; on
Dashboard in Day Cab (Black)
This is a ground connection. It is used as a power return (-) connection for
the vehicle's CB radio.
118
INSTRUMENTS AND CONTROLS
C0029240
C0029241
OPERATION 119
PRE-TRIP INSPECTION AND DAILY MAINTENANCE
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 Trucks 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).
120
OPERATION
Pre-Trip Inspection Quick List
Inspect the vehicle in a circular manner.
Approaching the Vehicle
• 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, 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.
• Check slack adjuster and chamber pushrod travel.
OPERATION 121
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, operating and of the proper color.
• Reflectors clean and proper color.
• Turn on headlights. High and low beams should be operating and lenses
clean. If equipped, check daytime running lights.
• Left and right front turn signal lights clean, operating 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.
• Check wheel bearing and hub: no obvious leaking on outside or inside
wheel. Verify correct oil level in hub.
Right Front Suspension
122
OPERATION
• 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.
• Check slack adjuster and chamber pushrod travel. 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.
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.
OPERATION 123
• 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.
• Check slack adjusters and chamber push rod travel. With brakes applied or
released, look for conspicuously different positions of the slack adjusters.
• Check spring brakes.
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: operating, clean and proper
color.
Step 7: Coupling System Area
Fifth Wheel
• Securely mounted to the frame.
124
OPERATION
• 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.
• 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.
• Check slack adjusters and chamber push rod travel. With brakes applied or
released, look for conspicuously different positions of the slack adjusters.
• Check spring brakes.
Condition of Visible Components
• Transmission: not leaking.
OPERATION 125
• 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.
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 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.
126
OPERATION
• Check steering wheel for excessive free play.
• Check for loose items in the cab. Secure them if necessary.
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 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.
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.
Spare Wheel(s)
• Carrier or rack not damaged.
OPERATION 127
• 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.
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.
128
OPERATION
• Check slack adjusters and chamber push rod travel. With brakes applied or
released, look for conspicuously different positions of the slack adjusters.
• Check spring brakes.
Step 12: Rear of Trailer Area
Lights and Reflectors
• Rear clearance, identification and tail lights clean, operating 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.
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
OPERATION 129
• 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.
• Check slack adjusters and chamber push rod travel. With brakes applied or
released, look for conspicuously different positions of the slack adjusters.
• Check spring brakes.
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
• Frame and crossmembers not bent, cracked, damaged or missing.
• Proper placarding.
• Body parts not damaged or missing.
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.
• 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.
130
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
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. 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 Trucks dealership so they can be checked
and corrected.
• Check the spring clip torque (U-bolts). (On REYCO suspensions, also check
equalizer nut torque.)
OPERATION 131
• On chassis equipped with AIRTEK™ front axle air suspensions, retorque
the U-bolts.
• Check the U-bolt torque on the MACK Trucks air suspension at the end of
the first 1600 km (1000 miles).
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.)
Note: On chassis equipped with AIRTEK™ front axle air suspensions, check the
torque of the front axle U-bolts at 24 000 kilometers (15,000 miles).
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 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 Trucks service center
as soon as any abnormal condition becomes evident.
Initial Valve Adjustment Intervals
Refer to the Maintenance and Lubrication Manual for detailed information
concerning the Initial Valve Adjustment Interval.
132
OPERATION
Disc Brake Check
Note: Your vehicle may be equipped with air disc brakes. If so please contact your
nearest MACK Trucks Truck dealer for service and maintenance information.
During each pre-trip inspection, the disc brakes should be checked for excessive brake
lining and rotor wear. To perform this check complete the following steps:
1 Each disc brake lining has a visual wear indicator. Find the visual wear indicator
and confirm that the lining is within specifications.
Note: The location of the lining wear indicator varies based on brake model. The
lining wear indicator can usually be found via a visual search. For additional
instructions on locating the lining wear indicator reference the brake manufacturer’s
service information. The two main brake manufacturer’s found on MACK Trucks
vehicles are Meritor and Bendix. Service documentation for each maker can be
found at their main internet site:
•
•
Meritor: http://www.meritor.com/customer/northamerica/default.aspx
Bendix: http://www.bendix.com
An example of (Meritor) indicator wear is shown below.
W5086049
Brake Pad Wear Indicator (Meritor)
1. New Condition
2. 25% Wear
3. 50% Wear
4. 75% Wear
Note: If the brake pad wear indicator shows 75% or more wear then the
pads require further inspection or replacement.
2. Examine the brake rotors for excessive wear and damage.
Inspect both sides of the rotor for excessive wear, heat checks, cracks, deep grooves or
scoring, and bluing. Light surface heat checks are normal and do not warrant service.
If the brakes or any part of the vehicle covered in the pretrip inspection are deemed
inoperable, take the vehicle for service at a MACK Trucks Trucks certified dealer.
OPERATION 133
WINDSHIELD WASHER RESERVOIR
As shown in the drawing below, the windshield washer reservoir is located
under the hood, against the rider-side cab bulkhead.
C0029314
134
OPERATION
HOOD OPERATION
Opening the Hood
To open the hood, release the locking tabs on each side of the hood.
C0029315
1. With the hood in the locked position, pull outward on the plastic handle and
disengage the locking tab from the hood latch.
2. Swing the rubber strap up and out of the way.
3. Repeat this procedure on the other side of the hood.
Note: When the hood is opened, the safety latch will drop down into the locked
position.
OPERATION 135
C0029924
4. Using the Bulldog as a handle, pull on the hood to raise it over the engine.
You may put one foot on the bumper if necessary.
5. Pull steadily on the hood until it comes over the center and stops fully open.
WARNING
NEVER take both feet off the ground to tilt the hood. Keep at least one foot on
the ground to avoid a slip or fall. If it is difficult for you to raise the hood, get
the help of someone who can lift from the rear of the hood.
WARNING
Little effort is required to open or close the hood. NEVER take both feet off
the ground to tilt the hood. Keep at least one foot on the ground to avoid
a slip or fall.
136
OPERATION
Closing the Hood
Note: Remember to remove all tools, rags and test equipment from the engine
compartment before closing the hood.
WARNING
Before closing the hood, be sure no one is in the way of the hood's descent.
Note: The safety latch must be released (reset) before the hood will close. (See arrow
in illustration.)
C0029317
OPERATION 137
Locking the Hood
To lock the hood, secure the rubber hold-down straps on each side of the hood.
1. With the hood down, set the rubber strap in position and force the locking
discs into the hood latch.
2. Push inward on the plastic handle to lock the rubber strap in place.
3. Repeat this procedure on the other side of the hood.
C0029318
CAUTION
Be sure the hood is latched securely. If the latch is not completely engaged, the
hood could open during operation and cause vehicle damage.
138
OPERATION
Closing and Locking Rear Fairing with Paddle
Handles
WARNING
Make sure the fairing/steps are
locked into position. Failure to lock
fairing/steps could result in personal
injury due to slip and fall.
CAUTION
To avoid component damage to the rear
fairing with paddle handles, ensure that
any overlapping rear fairings have been
opened first. Also, close the fairings
in reverse order; rear fairing with
paddle handles first and then any other
overlapping fairing.
To close and lock the fairings: Use your fingers to reach over the top of the fairing.
Locate the two paddle handles. Pull the handles up into the unlocked position as
indicated in the illustration. To close, push with your palms against the fairings. Once
the fairing is closed, make sure both handles are returned to the locked position. Also,
lightly tug on the lower fairing to ensure that the handle pin is properly seated.
W8072141
OPERATION 139
HOSE TENDERS
C0029319
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.
140
OPERATION
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.
OPERATION 141
Power Door Panel (Optional)
C0029322
Power Locks and Windows — Driver Side (Left) Shown
1. Manual Door Lock
5. Door Handle
2. Left Side Power Window Control
6. Door Light
3. Right Side Power Window Control
7. Storage Pouch
4. Power Door Lock
142
OPERATION
1. Manual Door Lock — Push backward to lock. Push forward to unlock. The
lock opening appears red when unlocked.
2. Left Side Power Window Control — Push back of button for DOWN,
front of button for UP.
3. Right Side Power Window Control — Push back of button for DOWN,
front of button for UP.
4. Power Door Lock — Push back of button to lock, front of button to unlock.
The power lock controls both doors.
Note: The right side (passenger) door has a power control for the right side window
only.
5. Door Handle — Lift handle to open.
6. Door Light — The door light automatically comes on when the door is
opened and goes out when the door is closed.
7. Storage Pouch — Large, rigid storage pouch.
Opening the Cab Door
To open the door, grasp the front of the door handle and pull upward.
Locking the Cab Door
The doors can be locked using the manual door lock (item 1 in the illustration)
or a power door lock switch (item 4 in the illustration).
Power door lock switches (on both sides of the cab) lock and unlock both cab
doors at the same time. To lock the doors, push the rear of the rocker switch.
To unlock the doors, push the front of the rocker switch.
To lock with the door open, push the lock lever forward and release. The lock
lever will return to the home position and the door will be locked when closed.
To unlock, pull the paddle and open the door.
WARNING
Always lock the doors while driving. This will lessen the chance of personal
injury. Locking the doors helps prevent the occupants from being ejected from
the vehicle in the event of an accident.
OPERATION 143
Power Window Regulators
To open the windows, push and hold the rear of the rocker switch (item 3 in
the illustration). To close the windows, push and hold the front of the rocker
switch. Release the rocker switch to stop the window at the desired position.
144
OPERATION
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).
OPERATION 145
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.
146
OPERATION
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:
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.
Troubleshooting
OPERATION 147
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.
Feature Programming:
1. Turn the ignition switch to the ON position.
148
OPERATION
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.
OPERATION 149
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 Trucks vehicles manufactured on or after September 1, 1990 must
have locking retractable seat belts.
For all seating positions in your MACK Trucks 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.
DANGER
Do NOT wear seat belt loosely. Do NOT use one belt for more than one person.
150
OPERATION
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.
OPERATION 151
Adjustable D-Ring Shoulder Belts (if equipped)
C0029327
The shoulder belt portion of the three-point belt is adjustable so that the belt
can be adjusted to lay properly and comfortably across the shoulder. To adjust
the belt, squeeze the release lock and move the belt to the desired position.
The belt locks into place when the lock is released.
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.
152
OPERATION
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.
D-Rings (If Equipped) — The height adjustors installed on pillars should
function smoothly without binding or signs of looseness.
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.
OPERATION 153
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.
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.
154
OPERATION
SLEEPER BUNK RESTRAINT
A sleeper bunk restraint is provided as a means of preventing ejection of an
occupant from the sleeper bunk during deceleration of the vehicle.
DANGER
To avoid personal injury, DO NOT occupy the sleeper bunk unless the restraint
is completely attached.
Upper Bunk (Optional)
The optional upper bunk is not intended to be used as a sleeping area or
storage area while the vehicle is moving and, therefore, is not equipped with
a bunk restraint.
DANGER
To avoid personal injury, DO NOT occupy the upper bunk or use it for storage
while the vehicle is moving.
DANGER
To avoid personal injury, use the bunk restraining strap to hold the upper bunk
in place when it is in the upright (stored) position.
OPERATION 155
Bunk Restraint Operation
Your vehicle is equipped with either a two-belt restraint system or a net
restraint system.
Two-Belt Restraint
• Pull each belt across the body and insert the tongue into the buckle until it
latches.
• Make sure that the tongue is securely fastened into the buckle.
• To release the belt, push down on the button.
To Attach Net Restraint
• Facing the mattress, arrange the webbing of the restraint on top of the
mattress so that the side with the two buckles (female ends) faces the rear of
the sleeper, and the side with the single buckle faces the passenger's side of
the vehicle.
• Fasten the two buckles to the two corresponding tongues (male ends)
attached to the rear wall of the sleeper.
• Fasten the buckle on the left side of the restraint to the corresponding tongue
attached to the passenger side wall of the sleeper.
• Fasten the tongue on the right side of the restraint to the corresponding
buckle attached to the driver's side wall of the sleeper.
• Fasten the three tongues along the nearside of the webbing to the
corresponding buckles attached to the front of the mattress area.
Bunk Restraint Maintenance
• Visually inspect the buckle and tongue for any damage which would impair
latching or unlatching.
• Check all hardware for breakage, distortion, or excessive corrosion.
• Ensure that fasteners are securely tightened in accordance with
specifications.
156
OPERATION
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.
HEATED SEAT (OPTIONAL)
If the vehicle is equipped with the optional heated seat which is available
only with the MACK Trucks Performance Seat, the controls are located on
the inboard side of the seat.
SWIVEL SEAT (OPTIONAL)
Both the driver-side and passenger-side seats can be swiveled 180° inboard.
(See drawing and instructions that follow.)
1. Recliner Handle — Before attempting to swivel, adjust the seat back to
near-vertical position using the lever or turn knob provided. After the seat is
swiveled into the desired position, the seat back may be reclined to a more
comfortable angle. (Position driver's seat away from steering wheel to allow
maximum recline.)
2. Swivel Latch — Unlatch by moving handle. Swivel inboard up to 120°.
Handle may be released after the seat begins to swivel.
CAUTION
If your vehicle is equipped with a sleeper and you are trying to gain access to the
sleeper from the cab, you must first adjust the seat midway between the fore and aft
positions. Then adjust the seat back to the vertical position, and finally, swivel the
seat to a position that will allow easy access to the sleeper. If these instructions are
not followed, damage to the driver seat and/or door panel can occur.
OPERATION 157
3. Fore/Aft Adjustment Lever — Fore (forward)/aft (backward) adjustment
may be required to provide clearance for the seat to swivel. Move the
adjustment knob to slide the seat fore and aft. After seat back and arm rest
have cleared B-pillar, seat fore/aft position may require readjustment to
provide clearance between knees and gearshift or dashboard and between
seat back and steering wheel.
4. Arm and Back Clearance — As the seat begins to swivel, check that the
seat back and armrest do not get hung up on the curtain or shoulder belt, or
contact the B-pillar or door.
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 seatbelt.
158
OPERATION
C0029328
Left Driver Seat Shown
1. Recliner Handle
3. Fore/Aft Adjustment Lever
2. Swivel Latch
4. Arm and Back Clearance
OPERATION 159
MACK Trucks ENGINE INFORMATION
For engine starting procedures, refer to “STARTING THE VEHICLE”, page
185.
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.
CAUTION
If a winterfront is used, a MACK Trucks-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.
160
OPERATION
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.
Engine Model Designations
The MACK Trucks 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 Trucks Power
3. Curve Family:
Econodyne = E
Maxicruise = C
Maxidyne = M
2. Peak Horsepower
4. Rounded Cubic Inch Displacement
OPERATION 161
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.
DANGER
DO NOT use the cruise control in
heavy traffic, with ice/snow on the
road or during other unfavorable
conditions. This may lead to a loss of
vehicle control, causing a vehicle crash,
personal injury or death.
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.
162
OPERATION
Setting Cruise Control
1. Press and release the brake pedal after engine has been started.
2. Engage the clutch (if equipped).
3. Move the Speed Control switch to the ON position.
4. Increase engine speed using the accelerator pedal.
5. 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.
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.
OPERATION 163
MACK Trucks 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 Trucks PowerLeash™ Engine
Brake, it is important that you take the time to become familiar with your
engine brake before putting it into .
WARNING
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.
164
OPERATION
MACK Trucks POWERLEASH™ ENGINE BRAKE
MACK Trucks MP7, MP8 and MP10 engines may be equipped with PowerLeash.
These engines are identified on the engine information sticker.
If your vehicle is equipped with the MACK Trucks 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 MACK Trucks PowerLeash™ 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.
OPERATION 165
Engine Brake Switch
Engine Brake Switch
1 OFF: No engine braking power
2 Medium: Half engine braking power
3 High: Full engine braking power
W8074176
Control Switch
To operate the vehicle without MACK Trucks PowerLeash™ Engine Brake active,
leave the dash-mounted switch in the OFF position.
The MACK Trucks 3 position (Off-Med-Hi) is used to turn the engine brake function
on or off, and to set maximum braking effort (50% or 100%). If the Control Switch is
on, the engine brake will activate automatically when the throttle pedal is released
and/or at 0%.
CAUTION
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.
166
OPERATION
How the Engine Brake is Activated
When the MACK Trucks PowerLeash™ Engine Brake is "enabled" (switch in
either Medium or HIGH position), your engine V-MAC® electronic control
system commands engine brake power (MACK Trucks PowerLeash™ 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 (5 mph)
If the MACK Trucks PowerLeash™ 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
MACK Trucks PowerLeash™ Engine Brake "active" conditions are again
true (taking your foot off the accelerator, for example), the MACK Trucks
PowerLeash™ Engine Brake will again be activated. In order to disable the
MACK Trucks PowerLeash™ Engine Brake, simply return the dash-mounted
control switch to the OFF position.
DANGER
The MACK Trucks PowerLeash™ 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.
OPERATION 167
Cruise Control with the MACK Trucks
PowerLeash™ Engine Brake
When the MACK Trucks PowerLeash™ Engine Brake is enabled at the same
time your V-MAC® cruise control is in use, the MACK Trucks PowerLeash™
Engine Brake automatically activates engage and disengage above the cruise
control set speed when necessary to slow the vehicle to the cruise set point
speed.
If the Set Switch is not depressed, this is the same functionality as today's
non-mDRIVE or mDRIVE Auto Mode vehicles, or a 3 mph over default.
Using the SET+ and SET- buttons, the default engagement speed can now be
raised or lowered to suit individual driver needs. The range limitation on this
parameter is 1 to 10 mph over the cruise control set MPH.
W4060025
The MACK Trucks PowerLeash™ 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 Medium 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: When the MACK Trucks® PowerLeash+™ Engine Brake is active and the
transmission is shifting gears, there will be a momentary interruption of the braking
torque. This may result in a temporary increase of vehicle speed if travelling downhill.
The operator will experience the same momentary loss of engine braking as is
experienced when downshifting a conventional manual transmission.
Note: Deactivating the cruise control function does not disable the MACK Trucks
PowerLeash™ Engine Brake.
168
OPERATION
The MACK Trucks 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.
Note: An exception exists if the vehicle is equipped with a Bendix Active Cruise
Control & Collision Warning system. If the vehicle is equipped with these features the
Bendix system will assume fueling and braking control when in active cruise control
mode regardless of the powerleash control switch setting to maintain following
interval.
OPERATION 169
MACK Trucks PowerLeash™ Engine Brake without
Cruise Control
This is a simplified 2 switch PowerLeash+ engine brake control. The standard MACK
Trucks 3 position 'Off-Med-Hi' CONTROL Switch, located to the left, is carried over
from non-mDRIVE vehicles and is used to turn the engine brake function on or off,
and to set maximum braking effort (50% or 100%).
If the Control Switch is on, the engine brake will activate automatically when the
throttle pedal is released and/or at 0%. This then functions identically to the current
MACK Trucks non-mDRIVE system.
The second (to the right) switch is the SET Switch. The SET Switch is a momentary
(press and release) switch with SET+ in the upper portion and SET- in the lower part
of the switch. When depressed, the Set Switch sets a target downhill set speed, and
braking effort will then vary from 0% to 100% to hold that set speed. Again, no
fueling input, no throttle input. If for example the current vehicle speed goes above
the set speed, the PowerLeash+ will be full on.
If current vehicle speed goes below the set MPH, the PowerLeash output will be
0%, At the set speed, the braking output will be variable (0-100%). Press SET+ to
further raise the target downhill speed, and SET- to lower it, and Co-Pilot will display
the current settings.
Note: The set speed is retained in memory even if the throttle is reapplied. It can only
be erased by turning the engine brake CONTROL Switch off, cycling the ignition key,
or automatically when vehicle speed drops below 30 mph. Once erased, the engine
brake will then automatically activate whenever throttle input is 0% (throttle released).
If the Set Switch is not used at all, there is no change in engine brake function vs
traditional MACK Trucks vehicles. If the Set Switch is used, PowerLeash+ functions
like a downhill cruise control, letting the driver set his downhill speed. Typically the
driver wants the set speed retained until it is reset or until highway driving ends,
hence the 30 mph “off ramp” reset.
W8074176
Control Switch
W8074177
Set Switch
170
OPERATION
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. Off
3. High
2. Low
As grades and vehicle weight increase, it will be necessary to use the HIGH
position.
W2074482
1. Off
2. Low
3. High
OPERATION 171
Descending a Grade
DANGER
The MACK Trucks 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 Trucks 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 MACK
Trucks PowerLeash™ 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.
C0029333
1. Descent Speed without MACK Trucks PowerLeash™ Engine Brake
172
OPERATION
Switch the MACK Trucks 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 with MACK Trucks PowerLeash™ Engine Brake
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.
OPERATION 173
On Slippery Road Surfaces
As with many aspects of operating a heavy-duty vehicle, special care should
be taken when using the MACK Trucks 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 Trucks 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 Trucks 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.
C0029332
1. Off
2. Low
3. High
174
OPERATION
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 the MACK Trucks PowerLeash™ Engine Brake switch position and
vehicle speed as necessary. Always test the LOW power position setting before
moving to the HIGH position.
Your MACK Trucks PowerLeash™ Engine Brake and ABS control systems
are designed to work together for optimized vehicle control. The engine brake
function will be interrupted briefly in the event of a wheel lock.
CAUTION
Do not enable the MACK Trucks PowerLeash™ Engine Brake during bobtail
operations, or when operating on slippery roads with an empty or lightly loaded
trailer.
OPERATION 175
BRAKE
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 276 ± 34 (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 483 kPa (70 ps)i. 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 138 – 207 kPa (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
CAUTION
Avoid sudden stops. Constant, sudden stops may negatively affect the performance
of braking and driving parts.
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.
176
OPERATION
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.
OPERATION 177
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).
Parking Brake
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.
178
OPERATION
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
When operating an ABS-equipped vehicle, the following guidelines should
be used.
• 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 178for more
information.
MACK Trucks Road Stability Advantage (If Equipped)
The MACK Trucks 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 Trucks 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
OPERATION 179
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
— 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.
180
OPERATION
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
operator's manuals so that the vehicle operator has a clear understanding as
to which ABS options are installed on the vehicle.
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.
Enhanced Stability Program
OPERATION 181
Enhanced Stability Program (ESP) is an optional system that uses existing
ABS and ATC components with the addition of electronic sensors and brake
valves. The system will automatically apply and release individual brakes
to improve vehicle control when extreme conditions are detected. In the
event a pending rollover situation is sensed, the system applies all brakes to
reduce vehicle speed to lessen the possibility of rollover. Please refer to the
applicable vendor manual for more information.
182
OPERATION
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 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
• 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.
OPERATION 183
Automatic Traction Control (ATC) (If Equipped)
W3001113
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
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.
184
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 190.
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 185
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.
186
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.
Priming the MP Fuel System
OPERATION 187
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.
188
OPERATION
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.
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
Trucks dealer.
OPERATION 189
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
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.
190
OPERATION
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.
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 Trucks 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.
OPERATION 191
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)
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.
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.
192
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. 1D fuel (kerosene) with 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 193
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.
• Reduces the temperature at which ether is required.
• Allows the engine heaters to be activated as soon as the engine is stopped.
194
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.
Note: The minimum operating temperature is 77°C (170°F).
If a winterfront is used, a MACK Trucks-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 195
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
Inside/Outside
Air
Prohibited
Available
Available
Suggested
Suggested
Can be Used
Recommended
Recommended
196
OPERATION
CAUTION
Winter treatments are NOT RECOMMENDED for vehicles which only operate
intermittently in cold climates. Sustained temperatures must be below -25°C
(-13°F).
CAUTION
Never fully close the winterfront if equipped with viscous fan drive.
For more information on winterfronts, please refer to the Maintenance and
Lubrication Manual .
ON-BOARD SCALES (OPTIONAL)
If your chassis is equipped with an optional Tractor Scale System, the
following gauge will be located on the D Panel directly above the radio box.
C0029339
Tractor Scale Display
Your chassis may be equipped with an optional Tractor Scale System. The
AW5800 on-board scale converts tractor and trailer suspension loads to an
accurate on-ground weight. By comparing empty and loaded axle group
weights with empty and loaded suspension pressures, the scale can be
calibrated to display accurate weights for any air suspension load.
For more information on this optional feature, please refer to the Air-Weigh
Installation, Calibration and Operations Manual..
OPERATION 197
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.
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.
198
OPERATION
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.
OPERATION 199
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.
12. Inspect the parked trailer to make sure the ground is supporting the trailer
and the landing gear is not damaged.
200
OPERATION
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.
OPERATION 201
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.
DANGER
If your vehicle is equipped with an Eaton® Fuller® Autoshift™ transmission,
selecting "D" on downhill grades will cause automatic upshifts. To prevent
unwanted upshifts, preselect "Manual" or "H". Engine must be kept below 2100
rpm to allow commanded upshifts. See the Eaton Driver Instructions manual
for more details.
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.
202
OPERATION
CAUTION
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.
OPERATION 203
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.
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.
204
OPERATION
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.
C0029340
1. Normal Clutch Pedal Travel
2. Depress Pedal last 13 mm (1/2 inch) to
25 mm (1 inch) to Engage Clutch Brake
(amount of clutch brake travel varies
depending on the system and overall
tolerances)
OPERATION 205
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 (approximately the last 13 mm (1/2 inch) to 25 mm (1 inch)
of pedal travel past normal, of clutch brake pedal travel, varies between the
air assist and non assist release systems. The variance includes general
tolerances and amount of pedal free-play. Typically about the last 13 mm
(1/2" inch) on the air assist and about the last 25 mm (1 inch) on the non
assist control systems).
Note: When the clutch is disengaged, a slight but definite resistance to clutch pedal
downward travel will be felt in approximately the last 13 mm (1/2 inch) to 25 mm
(1 inch).
CAUTION
Vehicles equipped with the air assist clutch control system use less pedal travel.
The clutch brake engages sooner in the pedal stroke than conventional non assist
systems. To avoid system damage, be careful not to engage the clutch brake during
normal shifting.
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
used to speed up the counter shaft for a downshift and to slow it down for an
upshift.
Note: For all non-synchronized 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.
206
OPERATION
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).
OPERATION 207
PTO Classification
Rear-mounted PTO units, for MACK Trucks 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.
208
OPERATION
TRANSMISSION SHIFTING INSTRUCTIONS
CAUTION
The maximum safe operating oil temperature for MACK Trucks 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 operator's manual
provided with your vehicle for complete shifting and operating instructions.
OPERATION 209
MACK Trucks 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.
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
210
OPERATION
MACK Trucks 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.
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.
OPERATION 211
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
212
OPERATION
MACK Trucks 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.
OPERATION 213
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
214
OPERATION
MACK Trucks 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.
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.
C0029344
TM309 TRANSMISSION RATIOS
OPERATION 215
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
216
OPERATION
MACK Trucks 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.
OPERATION 217
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
218
OPERATION
MACK Trucks 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.
OPERATION 219
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
220
OPERATION
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
OPERATION 221
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.
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.
222
OPERATION
MACK Trucks 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.
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.
OPERATION 223
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.
224
OPERATION
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
MACK Trucks 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.
OPERATION 225
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.
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.
226
OPERATION
• Select F or R as desired.
• Select lowest lever gear position.
• Release and depress clutch pedal.
• Select desired gear.
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 227
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.
228
OPERATION
MACK Trucks 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).
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.
OPERATION 229
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.
230
OPERATION
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.
C0029349
OPERATION 231
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
232
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 233
MACK Trucks 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.
234
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 235
C0029350
236
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 237
MACK Trucks 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.
238
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 239
C0029351
240
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 241
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.
242
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 243
MACK Trucks 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.
244
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 245
C0029352
246
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 247
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.
248
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 249
Precautions When Descending Grades If Vehicle is
Equipped with Eaton AutoShift Generation I and II
DANGER
When "D" is selected, AutoShift will automatically upshift as engine and road
speed increases on downhill grades.
Preselect "Manual" or "H" to prevent unwanted upshifts; use the up and down
buttons to command shift. Shifter will beep and not respond to shift requests that
will overspeed or excessively lug the engine.
Note: Keep engine speed below 2100 rpm to allow commanded upshifts.
Preselect "Low" to maximize engine braking power down steep grades and
allow downshifts only. See your Eaton Driver Instructions Manual for more
details.
250
OPERATION
AXLES
Rear Axles Other Than MACK Trucks
Please refer to the operator's manual provided with your vehicle for axles
other than MACK Trucks.
MACK Trucks Rear Axles
MACK Trucks 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
Trucks offers dual-reduction carriers in a variety of ratios.
MACK Trucks 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 Trucks
inter-axle power divider third differential (with or without a power divider
lockout).
MACK Trucks 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 Trucks 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.
OPERATION 251
Inter-Axle Power Divider Lockout (If Equipped)
The MACK Trucks 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.
252
OPERATION
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
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.
OPERATION 253
MACK Trucks, EPA2010 Emissions
Solution
DIESEL PARTICULATE FILTERS (IF EQUIPPED)
Your new MACK Trucks chassis is equipped with a 2010 emission compliant
engine, with an engine exhaust aftertreatment system (Diesel Particulate
Filter) and selective catalytic reduction (SCR) system. 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 offers two different types of DPF systems:
• Conventional DPF (passive regeneration and parked regeneration)
• Thermal Regeneration Unit (TRU) DPF (moving regeneration and parked
regeneration)
as well as two different mounting styles:
1. MACK Trucks Vertical Back-of-Cab DPF (both conventional DPF and TRU
DPF)
254
OPERATION
2. MACK Trucks-Cap DPF, which is a space saving 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 uses two exhaust aftertreatment systems:
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)
TRU exhaust aftertreatment systems use active regeneration. Regeneration
takes place after a certain number of engine operating hours and begins when
an air/fuel mixture is injected into the thermal regenerator and raises the
temperature inside the unit to the point where the soot oxidation takes place.
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).
OPERATION 255
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 repeatedly, the vehicle may need to be taken to a MACK
Trucks 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.
256
OPERATION
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
. Utilizing an engine speed above 1300 rpm is recommended for vehicles which
perform extended idling with an active PTO.
During periods of extended idling, normally greater than 8 hrs, 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 aftertreatment system
function and should not be stopped. ATS conditioning will not occur on TRU DPF
systems.
OPERATION 257
During these events the engine speed will increase to approximately 1050 – 1400
rpm, for non-PTO , 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 display is available
there will be no indication of an ATS conditioning event except for the automatic
increase in engine speed.
258
OPERATION
Exhaust Aftertreatment System
CXU Standard System View
W2029933
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, espically copper and brass. Read the separate section concerning the handling
of DEF solution.
OPERATION 259
Safety Information
MACK Trucks utilizes the use of a Diesel Particulate Filter (DPF) and Selective
Catalytic Reduction (SCR) to meet US2010 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.
260
OPERATION
Exhaust Aftertreatment System Components
and Operation
Aftertreatment Hydrocarbon Dosing System
W2064634
The aftertreatment hydrocarbon dosing system is a part of the exhaust aftertreatment
system and is used to increase the exhaust gas temperature (EGT) needed for the
aftertreatment system.
The dosing system allows diesel fuel to be injected into the exhaust system of the
engine to increase the amount of hydrocarbon (HC) released.
The injected fuel will increase the EGT by oxidation of hydrocarbon. An
aftertreatment diesel oxidation catalyst (DOC) is mounted upstream of the
aftertreatment diesel particulate filter (DPF). This elevated temperature is needed
for the aftertreatment selective catalytic reduction (SCR) system and DPF. The
HC-system shall be governed by the engine control module (ECM).
The dosing system has interfaces with a most of the vehicle's, major control systems
including the fuel system, compressed air system , exhaust system, electrical system,
control system and external mechanical interfaces.
OPERATION 261
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.
262
OPERATION
The MACK Trucks 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 near-zero 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 Trucks engine.
W2055490
Vertical SCR, side inlet
W2055491
Vertical SCR, vertical inlet
OPERATION 263
W2055492
Horizontal SCR, full size
W2055493
Horizontal SCR, compact size
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.
264
OPERATION
W3036787
Diesel Exhaust Fluid (DEF)
CAUTION
To Avoid Damage to Tank Do Not
Attempt to Top-Off Diesel Exhaust
Fluid (DEF). Diesel Exhaust Fluid
(DEF) expands when frozen and air
volume space at the top of the tank is
needed.
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.
OPERATION 265
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.
266
OPERATION
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.
Note: DEF tanks are sized for a two to one fuel to DEF ratio in order to meet US
2010 requirements.
CAUTION
To Avoid Damage to Tank Do Not
Attempt to Top-Off Diesel Exhaust
Fluid (DEF). Diesel Exhaust Fluid
(DEF) expands when frozen and air
volume space at the top of the tank is
needed.
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.MACK Trucksscr.com or please contact MACK Trucks
One-Call at 1–800–866–1177.
OPERATION 267
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. Manufacturers 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 Trucks Truck dealer
immediately.
268
OPERATION
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.
W2030326
OPERATION 269
Aftertreatment Control Module (ACM)
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 Pump
Aftertreatment DEF Return Valve
The ACM also monitors the following values in the exhaust aftertreatment system:
•
•
•
•
•
•
Aftertreatment DEF Dosing Pressure
Aftertreatment DEF Tank Temperature
Aftertreatment DEF Tank Level
Aftertreatment DPF Inlet/Outlet Temperature
Aftertreatment DEF Tank Level Sensor
Aftertreatment DPF Differential Pressure
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.
270
OPERATION
Exhaust Aftertreatment System
Aftertreatment DPF Regeneration
DPF Smart Switch– This is a three-position switch where the middle position
is neutral.
C0029148
DPF Smart Switch
1. Upper Position – Regeneration
Position
3. Down Position – Inhibit Position (if
equipped)
2. Middle Position – Neutral Position
CAUTION
During the Aftertreatment DPF Regeneration, the exhaust gas temperature will
be elevated. DO NOT park the vehicle with the exhaust outlet near flammable
objects such as trees, awnings, etc. that could be damaged by elevated exhaust
gas temperatures.
OPERATION 271
CAUTION
If the vehicle is in a location that may be hazardous when DPF Regeneration
begins (i.e., in close proximity to flammable materials or gases, inside tunnels,
parked under flammable objects, etc.), the DPF Regeneration should be stopped
(if equipped). If DPF Regeneration is stopped by the vehicle operator, it must be
initiated at a later time when the vehicle is in a safer location. DPF Regenerations
that are stopped and never restarted at a later time, however, will require that
the vehicle be taken to an authorized MACK Trucks Truck dealer to have the
Aftertreatment Regeneration manually started with special service tools.
Note: During vehicle operation, idle speed may increase when the vehicle is stopped
at a traffic light to maintain heat in the DPF for passive regeneration and urea dosing.
There are two types of Aftertreatment DPF Regeneration: Passive regeneration and
Parked regeneration.
Passive regeneration occurs when the exhaust gas within the aftertreatment system
is hot enough to remove soot without injecting additional fuel into the dpf system.
On chassis equipped with a US07 aftertreatment system, DPFs needed an active
regeneration, that included this injection of fuel. With the addition of the SCR system
active regenerations are no longer needed for US2010.
Parked Regeneration
The Aftertreatment DPF Regeneration system is self-monitoring. Under certain duty
cycles driver action is needed to perform a parked regeneration. When driver action is
needed to perform a parked regeneration, 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.)
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.
272
OPERATION
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. For aftertreatment DPF filter systems, the engine speed may ramp as high
as 1,250 rpm.
5. Parked regeneration will take between 30 and 45 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 (if
equipped). 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.).
Note: The HEST lamp will remain On if it comes On during the regeneration, and
remain On until the exhaust temperature returns to normal.
CAUTION
Failure to perform a regeneration in a timely manner after notification may result
in engine derate, a clogged DPF, damage to the DPF and engine shutdown.
OPERATION 273
DANGER
During the regeneration process, 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.
Note: Do not initiate a parked regeneration if the vehicle is in a location that may be
hazardous (i.e., in close proximity to flammable materials or gases),
If a parked 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 a parked regeneration is
stopped too many times, the vehicle must be taken to a MACK Trucks 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 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.
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.
274
OPERATION
DPF INHIBIT ROAD SPEED LIMITING (RSL)
The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen)
position by the driver (if equipped). 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.
Refer to the Exhaust Aftertreatment System Information sun visor label for additional
Aftertreatment DPF information.
W8056653
OPERATION 275
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.
276
OPERATION
Instrument Cluster
The aftertreatment icons are located in the instrument cluster per the following images.
CXU Instrument Cluster
W3031621
1. Malfunction Indicator
Lamp (MIL)
2. CHECK Lamp
4. High Exhaust
Temperature (HEST)
Lamp
5. Aftertreatment DEF
Tank Gauge
3. Aftertreatment DEF
Low Lamp
OPERATION 277
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
W3007444
High Exhaust System Temperature
(HEST) Icon
The Aftertreatment DPF Regeneration
Required icon flashes when the Diesel
Particulate Filter is full/overfull and
regeneration is needed.
Note: It is important to perform a
Regeneration when required to avoid
engine problems. Long-term engine
operation with Aftertreatment DPF
Regeneration required may result in
a loss of engine performance, reduced
horsepower, torque, speed and temperature
derate.
W3007445
Aftertreatment DPF Regeneration
Required Icon
The High Exhaust System Temperature
(HEST) Icon illuminates when the vehicle
exhaust temperature becomes excessive.
The icon also comes on during REGEN.
W2029416
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.
278
OPERATION
Malfunction Indicator Lamp (MIL)
W3031200
MIL Lamp
•
MIL indicates government Re gulation
On Board Diagnostics (OBD) faults
•
The MIL is illuminated when there is
an OBD related malfunction. When
a malfunction is detected the OBD
system shall store a pending code
and if the identified malfunction
is again detected before the end of
the next driving cycle, in which
monitoring occurs, the OBD system
shall illuminate the MIL continuously,
keep the pending code and store a
confirmed code. The MIL may not be
used for any other purpose.
•
If the malfunction is no longer detected
in a drive cycle and the following
two drive cycles, in which monitoring
occurs, the MIL will be turned off at
the next engine start. ( => Three cycles
to turn off the MIL).
•
Lamp may remain active after repair
until system confirms repair. The
driver should call the dealership
when the MIL is illuminated to
schedule time to repair the vehicle.
OPERATION 279
Aftertreatment Driver Warning and Inducement
Aftertreatment DEF Tank Level - Driver Warning
& Inducement
Aftertreatment DEF tanks are sized to have no less than two times the diesel fuel
tank mileage or one hour range.
The vehicle instrument cluster has an aftertreatment DEF tank level gauge.
Note: Repeated acts of tampering will result in more severe Inducement.
Triggers
Aftertreatment DEF
Tank Low Level
Indicator
Driver Information
Display Screen
100% to 12 % Aftertreatment
DEF Tank Level Gauge
None
None
DEF Tank Level Low
Refill DEF Soon to
Prevent Engine Derate
<=12 % Aftertreatment DEF
Tank Level Gauge
W2029416
Solid indicator
DEF Tank Empty
Refill DEF to avoid 5
Mph Limit
Engine in Derate
0% Aftertreatment DEF Tank
Level Gauge (~1% DEF
Remaining)
W2029415
Blinking indicator
280
OPERATION
Triggers
Aftertreatment DEF
Tank Low Level
Indicator
DEF tank empty and refueling
event with parking brake
applied
Driver Information
Display Screen
Refill DEF Tank
Vehicle Speed Limited
to 5 Mph
W2029415
Vehicle Stationary for 20
minutes or Engine re-start
(Key OFF, Key ON)
Refill DEF Tank
Vehicle Speed Limited
to 5 Mph
W2029415
OPERATION 281
Aftertreatment DEF Quality - Driver Warning &
Inducement
Triggers
Aftertreatment DEF
Quality Indicator
Driver Information
Display Screen
Good DEF Quality
None
None
Poor DEF Quality DTC
Initial Detected
SCR Performance Low
Engine will Derate in
___ mins
W3
031
623
Poor DEF Quality DTC
Initial Detected + 1 hours
SCR Performance Low
Engine In Derate
5 Mph Limit in ___
mins
W3
031
623
Poor DEF Quality DTC
Initial Detected + 4 hours
Note: Once this DEF
Quality fault occurs
the DID timer displays.
The timer displays the
minutes available before
the 5 mph derate occurs.
The timer can be cleared
using the Escape (ESC)
button on the stalk
switch control lever.
When the vehicle is
restarted after shutdown
the remaining minutes
before derate occurs will
reappear. For additional
DID information refer to
the Driver Information
Display Manual.
SCR Performance Low
Repair needed
5 Mph limit next
Vehicle Stop
W3
031
623
282
OPERATION
Triggers
Aftertreatment DEF
Quality Indicator
Refueling Event with Parking
Brake ON
Driver Information
Display Screen
SCR Performance Low
Service SCR System
Veh Speed Limited to 5
Mph
W3
031
623
Vehicle Stationary for 20
minutes or Engine re-start
(Key OFF, Key ON)
SCR Performance Low
Service SCR System
Veh Speed Limited to 5
Mph
W3
031
623
Temporary Exit from 8 Km/h
(5 mph) Inducement
W3
031
623
Ignition Key Cycle
SCR Performance
Evaluation
Continue Driving. 5
Mph Limit
Temporarily Removed
SCR Performance Low
Service SCR System
Veh Speed Limited to 5
Mph
W3
031
623
First start after the key cycle
(one time only)
W3
031
623
SCR Performance
Evaluation
Continue Driving. 5
Mph Limit
Temporarily Removed
Exit conditions for DEF Quality "8 Km/h (5 mph) road speed limit" Inducement:
Next 1 Engine Starts: Return to 25% torque reduction until there is a proper DEF
quality evaluation. If poor DEF quality is detected during the next monitoring cycle
then 8 Km/h (5 mph) is resumed after the vehicle is stationary for 20 minutes. After
one engine start has been exhausted then a Tech Tool is required to exit the 8 Km/h (5
mph) road speed limit.
With Tech Tool DTC Clearing: Invoke 25% torque reduction until there is a proper
DEF quality evaluation. If poor DEF Quality is detected during the next monitoring
cycle then 8 Km/h (5 mph) is resumed after the vehicle is stationary for 20 minutes.
OPERATION 283
Aftertreatment Tampering - Driver Warning &
Inducement
When the SCR tampering fault is active for one or more hours a new Driver
Information Display screen appears. The text changes for the Driver Information
Display (DID) screen associated with this fault are listed in the table below.
Triggers
Aftertreatment
Tampering Indicator
Driver Information
Display Screen
No Fault
None
None
Tampering Fault Detected
Note: For examples of
the various SCR sensor
tampering types refer to the
“SCR Sensor Disconnected
Tampering Type” table
below.
SCR System Fault
Engine will Derate in
___ mins
W3031200
284
OPERATION
Triggers
Aftertreatment
Tampering Indicator
Driving with Active Fault for
+ 1 hrs
Driver Information
Display Screen
SCR System Fault
Engine In Derate
5 Mph Limit in ___
mins
W3031200
Note: Once this SCR
tampering fault occurs
the DID timer displays.
The timer displays the
minutes available before
the 5 mph derate occurs.
The timer can be cleared
using the Escape (ESC)
button on the stalk
switch control lever.
When the vehicle is
restarted after shutdown
the remaining minutes
before derate occurs will
reappear.
Driving with Active Fault for
+ 4 hrs
SCR System Fault
Repair needed
5 Mph limit next
Vehicle Stop
W3031200
SCR System Fault
Veh Speed Limited to 5
Mph
1 Refueling Event (> 15 %
fuel level increase) with
stationary brake
2 Vehicle stationary for 20
minutes (vehicle speed <
1.6 Km/h (1 mph)
3 Ignition Key Cycle
W3031200
OPERATION 285
SCR Sensor Disconnected Tampering Type
Exhaust Temperature Sensors Disconnected
Aftertreatment Control Module (ACM) Disconnected
Aftertreatment NOx Sensor Disconnected
Aftertreatment NOx Sensor Disconnected
DEF Pump Disconnected
DEF Dosing Valve Disconnected
DEF Tank Level Sensor Disconnected
DEF Supply Line to DEF Pump Disconnected
DEF Return Line Blocked or Plugged
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.
Contamination of fluids by- misfilling of diesel or DEF in the wrong tank may result
in vehicle malfunction.
Results of misfilling DEF in Diesel Tank
•
•
•
•
•
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
Results of misfilling diesel in Aftertreatment DEF Tank
•
•
•
•
•
Aftertreatment SCR system may be damaged by Diesel
SCR Catalyst may be damaged by diesel (chemical damage)
Emissions may be non-compliant
On Board Diagnostic (OBD)Diagnostic Trouble Codes (DTC)
Costly repairs
286
MAINTENANCE AND LUBRICATION
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 Trucks 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 Trucks
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.
MAINTENANCE AND LUBRICATION 287
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. Pour clean engine oil into the oil inlet port at the top of the turbocharger
until overflowing.
2. Spin the compressor wheel by hand several revolutions while wiggling
the shaft back and forth. This ensures that oil is distributed over all bearing
surfaces.
3. Install the inlet air duct to the turbocharger, and install the turbocharger
drain tube (use a new gasket part No. 590GB2150). Make sure that all clamps
are tightened and positioned properly to ensure no leaks in the intake piping.
4. Disconnect the connector from the VTG control valve.
5. Again, pour clean engine oil into the turbocharger oil inlet port until
overflowing, and then reconnect the oil supply line.
6. Start the engine and allow it to run at an idle for at least five minutes.
Note: Disconnecting the connector from the VTG control valve prevents the
turbocharger from reaching excessive speeds when the engine is first started.
7. After the engine has run for at least five minutes, shut the engine off and
reconnect the VTG control valve connector.
8. Use the V-MAC® service tool to clear the fault code.
288
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 289
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
has approved EL-Ready Mix 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.
290
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 Trucks 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.
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.
MAINTENANCE AND LUBRICATION 291
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 Trucks 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 Trucks approved cleaning products
from your local MACK Trucks dealer.
292
MAINTENANCE AND LUBRICATION
TOWING
Vehicles not equipped with AMT-D and Vehicles equipped with AMT-D
without alternative emergency procedure:
The following towing procedure will have to be followed if vehicle is not equipped
with the AMT-D or if the vehicle is equipped with AMT-D without alternative
emergency procedure. Such vehicles will require removal of the drive shaft.
Note: Refer to label on Sun Visor or on the driver door to check if vehicle is equipped
with alternative emergency procedure.
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.
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.
MAINTENANCE AND LUBRICATION 293
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.
C0029420
Vehicles equipped with Automatic Towing Mode (AMT-D) with alternative
emergency procedure.
If the vehicle Cannot have the drive shaft removed and the vehicle is equipped
with AMT-D with alternative emergency procedure, please follow the procedure
below.
Note: Refer to label on Sun Visor or on the driver door to check if vehicle is equipped
with alternative emergency procedure.
This will allow the vehicle to be towed without the removal of the drive shaft for
whatever distance the vehicle need to be towed. The following conditions must be met.
Towing gear 3 HR will be engaged if following points are fulfilled:
•
•
•
•
•
Transmission neutral position
Vehicle moves forward faster than a set limit for a number of seconds
Engine is not running
There is enough pressure to the transmission
The key is on and power to the transmission control module (TCM).
CAUTION
Reverse towing is not allowed when such alternative emergency procedure is
applied. Reverse towing can damage the transmission.
294
MAINTENANCE AND LUBRICATION
Towing with MACK Trucks Air (AL or MAXAIR® 40)
Suspension (If Equipped)
During vehicle towing, when the rear axles of a chassis with the MACK Trucks
AL suspension are raised from the ground, the axle is held in position by the
fore-aft torque rods, transverse torque rod and the shock absorbers.
To prevent damage to any of these components during rear towing, the
following precautions should be taken:
• Exhaust the air from the air bags.
• Use chains of suitable length and secure the axles to the frame.
CAUTION
Be sure that the chains do not rub against spring members because this could
adversely affect spring member life.
CAUTION
Tow truck operators must be trained in proper hook-up techniques, safety
precautions, and the correct operation of their equipment to avoid vehicle damage
and personal injury.
MAINTENANCE AND LUBRICATION 295
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).
C0029422
296
MAINTENANCE AND LUBRICATION
Checking Power Steering Fluid
Proper fluid level should be between the lines on the dipstick.
Note: CHECK COLD
W2064870
1 Maximum Level
2 Minimum Level
MAINTENANCE AND LUBRICATION 297
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 Trucks 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.
298
MAINTENANCE AND LUBRICATION
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, 2007 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.
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.
MAINTENANCE AND LUBRICATION 299
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.
Use of Biodiesel for MACK Trucks US2010 Certified
Products
MACK Trucks 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 Trucks does not warrant the engine will conform to applicable
Federal or California emissions limits when operated on, or having been 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
manufacturer's mechanical warranty as to engine or emissions system, provided the
bio fuel used in the blend conforms to ASTM D6751, and B1 to B5 blends conform to
ASTM D975, and B6 to B20 blends conform to ASTM D7467.
Customers will need to utilize oil sampling to establish appropriate drain interval(s)
for their application(s).
300
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.
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.
MAINTENANCE AND LUBRICATION 301
Coolant Level Check
WARNING
Turn the cooling system pressure cap counterclockwise slowly. After the
pressure has completely dissipated, continue turning to remove the cap.
Your MACK Trucks model chassis has a pressurized plastic coolant expansion
tank where quick checks of coolant level can be made and additional coolant
can be added to the system. The expansion tank is mounted on the radiator.
Periodically, the coolant level should be checked by observing the coolant
in the expansion tank.
C0029425
1. Expansion Tank
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.
302
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 Trucks 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 303
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 Trucks 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 ..
304
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
C0029426
Accessory and Main Drive Belt Routing
1. Accessory and Main Drive Belt Routing MP8 Engine
MAINTENANCE AND LUBRICATION 305
HEADLIGHTS
Bulb Replacement
Note: The long-life halogen bulbs can be replaced without tools.
CAUTION
Never touch the glass of a halogen bulb with your bare hands or a dirty rag. Oils
and other contaminants can greatly reduce bulb life or cause the bulb to explode.
• Open the hood. To access the headlight area, remove the wing nut on the
headlight housing cover and lift the cover.
• Remove the electrical connector.
• Turn the appropriate bulb holder counterclockwise to remove the bulb.
Reverse this procedure for reinstallation.
LICENSE PLATE MOUNTING
If a license plate is required on the front bumper, it can be mounted as follows:
• Use the license plate as a template to locate the position of the required
mounting holes.
• Drill 8.70 mm (11/32-inch) holes in the bumper.
• Fasten the plate with M6x1 Steel Plusnuts and M6x1 30-mm Steel
Capscrews.
306
MAINTENANCE AND LUBRICATION
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 307
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.
308
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.
Subjects of interest are:
• High-speed or low-speed operation
• Repair, retreading and regrooving
• Use of tire chains
• Mixing radial and bias tires on the same vehicle
• Use of dynamometers
• Tire mounting/dismounting
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:
MAINTENANCE AND LUBRICATION 309
• Axle end seals
• Engine seals
• 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.
310
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.
The battery cover may also be a base for the cab steps. To remove the cover, unhook
the two rubber latches and lift the cover up and out. This applies to the CXU vehicle.
DANGER
When installing the battery cover,
make sure it is resting properly on
the box before fastening the latches.
Faulty installation may cause the
cover to shift when the steps are used,
which may lead to a fall, causing
serious personal injury or death.
W3005504
W3005334
The CXU vehicle has two styles of battery boxes available. One is covered with a
plastic cover, the other cover is polished aluminum.
MAINTENANCE AND LUBRICATION 311
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.
Note: Your vehicle may be equipped with a jump-start connector which is located
on the left rear side of the cab.
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.
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.
312
MAINTENANCE AND LUBRICATION
ELECTRICAL
Circuit Breaker and Relay Panels
The electrical equipment cover for this vehicle is located in the middle of the
dash under the top cover.
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.
C0029433
MAINTENANCE AND LUBRICATION 313
C0029434
1. Front
2. Back
314
MAINTENANCE AND LUBRICATION
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.)
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.
MAINTENANCE AND LUBRICATION 315
Circuit Protection Charts
Cab Circuit Protection
#1
#2 – 15A
#3 – 15A
#4 – 20A
Open
Headlamps, DRL
Module, Fog
Lamps
Park & Tail Lps.,
Marker Lamps
Direct Lps.,
Flasher
#5 — 10A
#6 — 10A
#7 — 10A
#8 — 15A
Tractor Stop Lps.
Dome Lps.,
Courtesy Lps.
Ign. Switch
Air Solenoid
#9 — 15A
#10 — 5A
#11 — 15A
#12 – 10A
CB Posts
Communication
Connector (DDL),
Radio
Battery Stud
Electric Door
Locks
#13 – 20A
#14
#15 – 20A
#16 – 10A
ABS
Open
Heated Mirrors
Vehicle Control
Unit (VCU)
#17 – 10A
#18 — 10A
#19 — 5A
Clutch Switch, Engine Brake, Cruise
On/Off & Set/Resume, Override
Switch, Park Brake, PTO w/o T2000,
Spare (VCU) Relay Coils
DPF Switch
Power/Spare
ABC Cluster
#20 – 10A
#21 — 20A
#22 — 20A
#23 — 20A
Moto Mirrors
Windshield Wiper
& Washer
LH Window Lift
Motor
RH Window Lift
Motor
#24 — 15A
#25 – 40A
#26 — 15A
#27 — 15A
Spare Batt./Ign.
Power
Heater/Air
Conditioner
Hook-Up Lps.
Ignition Stud
316
MAINTENANCE AND LUBRICATION
Cab Circuit Protection
#28 — 20A
#29 — 10A
#30 — 20A
#31 — 15A
Htd. seats
EMS #1 Relay
Coil/Short Range
Wireless
Opt. Ign. Power
Sw., Spare
Auto shift trans.
or spare
#53 — 15A
#60 — 20A
#61 — 20A
#62 — 15A
A/C Comp.
Clutch
2-Power Outlet
Sockets
Aux. sw's/Spare
Spare/Battery
#63 — 5A
#64 — 10A
#65 — 15A
#67 — 15A
ABC Gauge
Cluster
Cold Start
VORAD Module
Spare/Battery
#68 — 15A
#69 — 10A
#70 – 30A
#71 — 15A
Cigar Lighter
Keyless Entry
Module
HVAC Sleeper
Transmission
#72 — 10A
#74 — 5A
HVAC/Control
Unit
Illumination
MAINTENANCE AND LUBRICATION 317
Engine Circuit Protection (V-MAC IV)
#32 — 30A
#33 — 30A
#34 — 30A
#35 — 30A
Spare Body Bld.
Trailer Stop Lps.
Reverse/Neutral
Power
Cab & Trailer
Clearance Lps.
#36 — 15A
#37 — 30A
#38 — 25A
#39 — 30A
Horn
Trailer Tail Lps.
Engine Control
Unit (ign.)
Trailer ABS
Power
#40 — 15A
#41 — 15A
#42 — 20A
Spare
Engine Compartment
Back-Up Lps.
#43 — 10A
#44 — 25A
#45 — 30A
#46 — 20A
Engine
Compartment
Air Dryer, Htd.
Drain Valve
Fuel Heater
NOx
Sensor/Spare
#47 — 10A
#48 — 50A
#49 — 10A
#50 — 10A
Meritor Trans.
EOA or Spare
Sleeper Box
ABS
Low Beam L.H.
#51 — 10A
#52 — 15A
Low Beam R.H.
Spare/Guard Dog
318
MAINTENANCE AND LUBRICATION
Electrical Accessory Connection Points
CAUTION
The electrical systems on all MACK Trucks chassis include a circuit breaker
located in the ground circuit. Any additional electrical components that may be
added MUST not be connected directly to the battery or negative connection of
the starter. Doing so may defeat the protection provided by this circuit breaker.
Components may be ground connected to other locations, such as frame or engine
grounding points.
All MACK Trucks chassis are equipped with convenient connection points
for installation of electrical accessories. For the installation of any electrical
accessories, use only the designated battery post (+12v), ground post, CB
jack, buffered RPM outputs, buffered MPH outputs, and the SAE/ATA J-1708
post, located on the electrical equipment panel. Location of the electrical
equipment panel varies by vehicle. Refer to the specific model operators
manual (provided with each chassis) for the exact location of the electrical
equipment panel. A description of each connection point follows.
Battery Post (BATT)
This is a +12 volt unswitched battery power connection. It can be used to
power external devices that require power at all times, regardless of ignition
switch position. This source is protected by a 20-amp circuit breaker.
Ignition Post (IGN)
This is a +12 volt switched battery power connection. It can be used to power
external devices that require power only when the ignition switch is in the ON
position. This source is protected by a 15-amp circuit breaker.
Ground Post (GND)
This is a ground connection. It can be used as a power return () connection
for external devices.
WARNING
The tachometer output, speedometer output, and serial links A and B are
for specific hookups. These terminals should be used only for their specified
purposes and connection to these terminals should be done only by a qualified
service technician.
MAINTENANCE AND LUBRICATION 319
Note: The tachometer output and speedometer output are 50% duty cycle,
Transistor-Transistor Logic (TTL) compatible, square wave signals that are calibrated
to provide a standard pulse rate of 12 pulses per engine revolution for the tachometer
output and 30,000 pulses per mile for the speedometer output. TTL compatibility of
these outputs may be affected by other devices connected to these outputs.
Tachometer (RPM) Output
This is a 50% duty cycle, 5-volt Transistor-Transistor Logic (TTL) compatible,
square-wave signal, that is calibrated to provide a standard pulse rate of 12
pulses per engine revolution.
Note: TTL compatibility of this output may be affected by other devices connected to
this output. Maximum rated current of the TTL output is 10 mA. Total current draw of
all devices connected to this output must not exceed 10 mA at 4 volts.
Speedometer (MPH) Output
This is a 50% duty cycle, 5-volt TTL compatible, square-wave signal, that is
calibrated to provide a standard pulse rate of 30,000 pulses per mile.
Note: TTL compatibility of this output may be affected by other devices connected to
this output. Maximum rated current of the TTL output is 10 mA. Total current draw of
all devices connected to this output must not exceed 10 mA at 4 volts.
SAE/ATA J1708 Posts (Serial Links A and B)
his is a serial communication interface. It conforms to the SAE/ATA
J-1708 Recommended Practice for Serial Data Communications Between
Microcomputer Systems in Heavy Duty Vehicle Applications.
CB Radio Power Jack
The CB radio power jacks are located on the dashboard of the day cab, and
on the headliner of the sleeper.
Power Jack (+) This is a 12-volt, switched battery connection. It is to be used
to power the vehicle's CB radio. It is protected by a 15-amp circuit breaker and
will supply power when the key is in the ACCESSORY position or ON position.
Power Jack (-) This is a ground connection. It is to be used as a power return
connection for the vehicle's CB radio.
320
MAINTENANCE AND LUBRICATION
Optional Body Builder Connectors (BBM-PK16
Option)
The BBM-PK16 body builder option includes additional body builders signals located
in two connectors located on the chassis cross member behind the cab.
W3085785
Optional Body Builder Connectors
(BBM-PK16)
MAINTENANCE AND LUBRICATION 321
The following signals are included in the
two connectors:
W3085786
Primary Body Builder Connector
(BBPA1)
Pin
Description
A
Ground
B
Tail Lamp
C
Clearance Lamp
D
LH Turn/Stop
E
RH Turn Stop
F
Reverse Power
G
Rear Flashing
H
Stop Lamp
322
MAINTENANCE AND LUBRICATION
W3085786
Auxiliary Body Builder Connector
(BBPA2)
Pin
Description
A
Ground
B
Clearance Lamp
C
Salt Spreader (Spin)
D
Beacon
E
Tarp In Switch
F
Tarp Out Switch
G
Power Float
H
-
The electrical components and wiring
controlling the signals mentioned above
are included in the vehicle’s electrical
system.
The switches controlling these signals are
installed in the instrument panel, left of
the radio and are pre-wired in the vehicle.
METRIC CONVERSIONS 323
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.
324
METRIC CONVERSIONS
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
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement