2010 US Mack Pinnacle Series (CXU Series) Operator's Manual
2010 US Mack Pinnacle Series (CXU Series) Operator's Manual
2010 US Mack Pinnacle Series (CXU Series) Operator's Manual
®
Mack Pinnacle Series
® TM
Mack Pinnacle Series
® TM
21394648
The information in this manual applies to vehicles built April 2010 and later.
Please keep this manual in the vehicle at all times.
Note: Illustrations in this manual are used for reference only and may
differ slightly from the actual vehicle. However, key components
addressed in this document are represented as accurately as possible.
The National Highway Traffic Safety Administration (NHTSA) and
MACK Trucks Inc. should be informed immediately if you believe that
the vehicle has a defect that could cause a crash, injury or death.
Contact NHTSA by calling the Auto Safety Hotline at 1 (888)
327-4236, by writing to NHTSA, U.S. Department of Transportation,
Washington, DC 20590, by TTY at 1 (800) 424-9153, or visit their
website at www.nhtsa.dot.gov.
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.
TO THE OWNER
In Appreciation
Thank you for buying a MACK® 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 distributor if a question arises. Honest, personal service is standard
with every MACK sale.
CAUTION
Mack Trucks, Inc. would like to point out the important role that the driver plays in
the life of the vehicle. Only trained and informed drivers should operate this vehicle.
We, at Mack Trucks, Inc., hope that you will be happy with your new Mack®
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
Note: Basic maintenance and lubrication procedures are found in this manual
beginning with “MAINTENANCE INTRODUCTION”, page 261. For further
information, refer to the Maintenance and Lubrication Manual (TS494). Other
important information can be found in the Emission Control Systems for MACK
Diesel Engine Manual (TS505).
INTRODUCTION 3
THE VEHICLE
Basic Configuration
The Mack® Pinnacle™ model features a conventionally styled, aerodynamic cab.
WARNING
Never cut into the V-MAC system wire harness to power additional equipment. If
such equipment is to be installed, contact your MACK dealer for assistance.
4 INTRODUCTION
COMPONENT IDENTIFICATION
Locate the following serial numbers and write them in the boxes provided next
to each illustration.
VIN Locations
The Vehicle Identification Number (VIN) is displayed in two locations (a frame
rail stamping and a label). The 17-digit VIN must be identical in both locations.
The VIN frame stamping is located on the 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.
INTRODUCTION 5
C0028941
Engine Identification
On the MACK MP engines, the engine serial number is stamped on the left
side of the engine block, below the inlet manifold.
C0028943
6 INTRODUCTION
C0028944
C0028945
C0028946
Transmission Identification
The MACK T300 Series transmission serial number is located on the rear
left side of the main case.
C0028947
C0028948
C0028949
INTRODUCTION 9
The MACK carrier assembly serial number is located on the front right side
of the housing.
C0028950
The Eaton® Spicer® rear axle serial number is located on the rear of the
axle housing toward the carrier.
C0028951
The Eaton® Spicer® carrier assembly serial number is located on the left
side of the forward carrier, and the top of the rear carrier.
C0028952
The MERITOR rear axle identification tag is located on the left or right rear of
the rear axle housing, next to the carrier.
10 INTRODUCTION
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
INTRODUCTION 11
WARRANTY INFORMATION
This chassis is equipped with a US’07 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.
SERVICE LITERATURE
The MACK Service Publications department offers a variety of service literature
(including individual service manuals) that can be ordered through any MACK
dealer or on the Mack Trucks, Inc. website at www.macktrucks.com.
Note: Mack Trucks, Inc. would like to emphasize the importance of proper service
and maintenance procedures. Service, repair and replacements must be performed by
certified, licensed mechanics in accordance with MACK standards.
CUSTOMER SERVICE
Addresses
The addresses, telephone and fax numbers of the Mack Trucks, Inc. regional
offices are:
United States
Northeast Region – 2100 Mack 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 Canada, Inc., 5600A Cancross Court, Mississauga,
ON L5R 3E9, TEL: (905) 366-3400, FAX: (905) 366-0165
Australia
Mack Trucks Australia Pty. Ltd., CNR Archerfield and Boundary Roads, Mail:
P.O. Box 364, Richlands, QLD 4077, Australia, TEL: 61-7-3853-3333, FAX:
61-7-3853-3392
International
2100 Mack Blvd., Mail: P.O. Box M, Allentown, PA 18105-5000, TEL: (610)
709-3405, FAX: (610) 709-2323
Additional Assistance
If additional assistance is required, Mack Trucks, Inc. maintains a Customer
Service Department (staffed by experienced personnel) to aid customers who
need information or assistance not provided at the local or regional level.
The Customer Service Department phone number is (610) 709-3961.
When contacting the regional service offices or Customer Service Department,
provide the following information:
United States
If you believe that your vehicle has a defect which could cause a crash, injury
or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA), in addition to notifying Mack Trucks, Inc.
If NHTSA receives similar complaints, it may open an investigation and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your distributor, or Mack Trucks, Inc.
To contact NHTSA, either call the U.S. Government’s Vehicle Safety
Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to
http://www.NHTSA.gov; or write to: Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590.
You can also obtain other information about motor vehicle safety from the
Vehicle Safety Hotline.
Canada
Canadian customers who wish to report a safety-related defect to Transport
Canada — Defect Investigations and Recalls, may telephone the toll free
hotline at 1-800-333-0510, or contact Transport Canada by mail at Transport
Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa ON K1A
0N5. For additional road safety information, please visit the Road Safety
website at http://www.tc.gc.ca/roadsafety/menu.htm.
Mexico
Volvo 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 Volvo Trucks de Mexico by calling 011-52-55-50-81-68-50
or by writing to: Volvo 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 17
SAFETY STATEMENT
Mack Trucks, Inc. cannot anticipate every possible occurrence which may
involve a potential hazard. An accident can be avoided by recognizing
potentially hazardous situations before a dangerous situation occurs.
Correctly performed service procedures are critical for technician safety and
safe, reliable operation of the vehicle.
DANGER
Do not operate the engine in an enclosed area. All internal combustion engines
give off various fumes and gases while running. Inhalation of exhaust fumes can
cause death.
DANGER
Do not sit in a parked vehicle for any extended amount of time with the engine
running if there are leaks in the exhaust system. Exhaust fumes could leak into the
cab area and death can result. On a regular basis inspect the exhaust system for
leaks and repair any leakage.
DANGER
Driver attitude is the most important part of any effective vehicle safety system.
Mack Trucks, Inc. strongly encourages all drivers and passengers to use their seat
belts, drive defensively, remain alert and respect the speed limits. Many accidents
can also be avoided through regular vehicle maintenance.
DANGER
Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts,
driveshafts and other related rotating assemblies, can be very dangerous. Do not
service engine-driven components unless the engine is shut down. Always keep
body parts and loose clothing out of range of these powerful components to prevent
serious personal injury. Be aware of PTO engagement or nonengagement status.
Always disengage the PTO when not in use.
SAFETY INFORMATION 19
WARNING
Certain everyday procedures such as washing the vehicle and cleaning the
windshield can also be hazardous because of the vehicle’s height. Mack Trucks,
Inc. does NOT recommend climbing up on the vehicle to perform these operations.
Instead, stand on the ground and use brushes and squeegees mounted on extension
poles. When better access is necessary (for instance, when washing the cab roof),
use sturdy ladders held in place by someone on the ground.
WARNING
Secure loose objects. Loose objects in the cab or sleeper can be dangerous in a
sudden stop or on bad roads. Secure any appliance added to the vehicle, such as a
refrigerator or a radio.
WARNING
Keep clear of fan when engine is running. Fan may start to rotate at high speed
without warning.
20 SAFETY INFORMATION
CERTIFICATION LABELS
Incomplete Vehicles
C0028955
Completed Vehicles
In addition to the label supplied by Mack Trucks, Inc. as the chassis-cab
manufacturer, a Completed Vehicle certification label, supplied by the body
manufacturer, is affixed in the same general location. This label provides
information pertaining to Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR), tire and rim information, etc.
On MACK-completed vehicles, this label contains the date of manufacture,
VIN, GVWR, GAWR, and tire and rim data. It is found in one of the NHTSA
locations listed above.
C0028956
22 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® Pinnacle™ model
chassis at the time of publication and are representative of what can be
typically found on a Mack® 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.
C0028957
24 SAFETY INFORMATION
C0028958
SAFETY INFORMATION 25
C0028959
26 SAFETY INFORMATION
C0029012
SAFETY INFORMATION 27
C0029922
C0029014
SAFETY INFORMATION 29
C0029015
30 SAFETY INFORMATION
C0029016
SAFETY INFORMATION 31
C0029017
C0029018
Note: Label to be removed upon delivery to the end user. Refer to “BRAKE
OPERATION”, page 152 in the OPERATION section for additional information.
32 SAFETY INFORMATION
C0029019
C0029020
SAFETY INFORMATION 33
C0029021
Your chassis may be equipped with an optional back up alarm. If so, the
following label will appear inside the cab.
C0029022
C0029923
34 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
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 35
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.
36 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 37
Driver Side
The following cab entry and exit procedures, along with the safety guidelines
outlined in Three-Limb Contact earlier in this section, should be used with
this MACK vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with 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.)
38 SAFETY INFORMATION
C0029024
SAFETY INFORMATION 39
Passenger Side
The following cab entry and exit procedures, along with the safety guidelines
outlined in the Three-Limb Contact section, should be used with this MACK
vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with 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.)
40 SAFETY INFORMATION
C0029025
SAFETY INFORMATION 41
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.)
42 SAFETY INFORMATION
C0029130
SAFETY INFORMATION 43
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.
44 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.
C0029131
SAFETY INFORMATION 45
C0029132
46 SAFETY INFORMATION
C0029133
If the kit is installed from the factory, it includes red reflector triangles and can
be stored in one of the following locations:
CAB INTERIOR
C0029134
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:
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 49
C0029135
50 INSTRUMENTS AND CONTROLS
Panel A
C0029136
Panel B
W3030489
52 INSTRUMENTS AND CONTROLS
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 30. Fasten Seat Belt Warning
(Amber) Indicator (Red)
16. Anti-Lock Brake System (ABS) 31. HEST Indicator (If Equipped)
Indicator (Amber)
17. Low Coolant Level Indicator 32. Fuel Gauge
(Amber)
18. Coolant Temperature Gauge 33. Mode Button (Basic Display Only)
Panel C
C0029138
36. Air Application or Air Suspension 39. Rear Rear Axle Oil Temperature
Gauge (If Equipped) Gauge (If Equipped)
37. Hand-Control Brake Lever 40. Primary Air Pressure Gauge
38. Front Rear Axle Oil Temperature 41. Secondary Air Pressure Gauge
Gauge (If Equipped)
54 INSTRUMENTS AND CONTROLS
Panel D
C0029139
* 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 77 for a
description of the optional switches, listed in alphabetical order.
56 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 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).
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.
CAUTION
The maximum safe oil temperature for MACK transmissions is 121°C (250°F) for
mineral-based oil, or 148°C (300°F) for synthetic oil. Continued operation with
oil above this temperature will cause rapid deterioration of the oil’s lubricating
properties and is NOT recommended. Consult the vendor manual for non-MACK
components.
Note: Consult the appropriate vendor engine manual if your vehicle is not equipped
with a MACK 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.
58 INSTRUMENTS AND CONTROLS
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 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 59
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.
C0029140
60 INSTRUMENTS AND CONTROLS
• Trip Information
C0029141
INSTRUMENTS AND CONTROLS 61
• Diagnostics
C0029142
62 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, TS898.
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 63
• If the engine is started to soon for the system to complete a proper engine
level reading the following screen displays.
W1030391
W1030395
64 INSTRUMENTS AND CONTROLS
W1030406
W3030649
C0029146
HEST Indicator
32. Fuel Gauge – Registers the fuel level in the supply tank(s).
66 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, TS898.
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 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 components.
INSTRUMENTS AND CONTROLS 67
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
43. DPF Smart Switch (If Equipped) – This is a three-position switch where
the middle position is neutral.
C0029148
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.).
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.
70 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 71
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 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.
72 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.
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 73
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, TS898.
74 INSTRUMENTS AND CONTROLS
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.
C0029150
76 INSTRUMENTS AND CONTROLS
74. Speed Control Switch – This is a V-MAC® switch; refer to the V-MAC®
IV Operator’s Guide (TS898) for more information.
C0029211
INSTRUMENTS AND CONTROLS 77
C0029212
Optional Switches
C0029213
Optional Switches
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.
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 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.
82 INSTRUMENTS AND CONTROLS
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
• 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%.
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.
84 INSTRUMENTS AND CONTROLS
C0029218
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 85
C0029219
1. Directs airflow through the dash 4. Directs airflow through the floor
panel air vents only. vents and the windshield for defrosting
and/or defogging.
2. Directs airflow through both 5. Directs airflow only to the
the dash panel and floor air vents windshield for defrosting and/or
(bi-level). 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.
Note: When using the sleeper air conditioner, this switch must be turned ON.
86 INSTRUMENTS AND CONTROLS
C0029220
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.
INSTRUMENTS AND CONTROLS 87
C0029221
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.
88 INSTRUMENTS AND CONTROLS
C0029222
STEERING COLUMN
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.
WARNING
Adjust the steering wheel position BEFORE attempting to move the vehicle
to avoid losing control of the vehicle.
The turn signal lever is located on the steering column. It performs a number
of functions, including activating the high and low beams, signal switch and
the hazard switch. The signal switch can be used for courtesy flashing of
marker lights and for the flashing of high beams.
C0029224
C0029225
INSTRUMENTS AND CONTROLS 91
1. Handle in Right Turn Position and 4. Push for Courtesy Flashing of High
Cancel Position of Hazard Warning Beams
2. Handle in Left Turn Position and 5. Push for Courtesy Flashing of
Cancel Position of Hazard Warning Marker Lights (Daylight or Dark)
3. Pull for Warning Hazard Position 6. Lift Handle for Headlight Dimmer
C0029226
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.
92 INSTRUMENTS AND CONTROLS
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, TS898.
INSTRUMENTS AND CONTROLS 93
FLOOR PEDALS
C0029227
MISCELLANEOUS CONTROLS
Dome Light
C0029228
Dome Light
C0029229
C0029230
C0029231
Driver Side
1. Map Light Switch Activates the 3. Sleeper Light Switch Activates the
map lights (which are located in the sleeper ceiling lights.
headliner, to the left of sun visor).
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.
96 INSTRUMENTS AND CONTROLS
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
INSTRUMENTS AND CONTROLS 97
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.
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, please refer to the Radio Manual that is supplied with the vehicle.
98 INSTRUMENTS AND CONTROLS
C0029236
C0029238
INSTRUMENTS AND CONTROLS 99
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.
C0029240
C0029241
OPERATION 101
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 Volvo 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).
102 OPERATION
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.
• 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.
Grille
• Check that charge air cooler and radiator or bugscreens are clean and
undamaged.
104 OPERATION
• Check air filter with brackets and hoses for loose connections or damage.
Check filter gauge, if mounted on the filter.
Suspension
• Check condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
106 OPERATION
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 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.
• Air tubing and electrical wiring: secured against snagging and chafing.
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.
OPERATION 109
• Apply service brakes. After initial drop, pressure should hold steady, or
increase slightly, with engine at idle.
• 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.
Note: Refer to the trailer manufacturer’s manual for specific information on the
trailer checks.
Spare Wheel(s)
• Carrier or rack not damaged.
• Spare wheel securely mounted in rack.
• Tire and wheel condition adequate for a spare: proper size, properly inflated.
Suspension
OPERATION 111
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.
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.
112 OPERATION
Suspension
• Condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
• Condition of torque rod arms.
• If equipped with sliding axles, check position and alignment. Look for
damaged, worn or missing parts, all locks present, fully in place and locked.
• Flexible air tubing not cracked, cut, crimped or otherwise damaged. It should
be secured against tangling, dragging and chafing.
Brakes
• Condition of brake drums. With brakes released, look for a noticeable gap
between lining and drum. (This check can not be made if dust covers are
in place.)
• Condition of brake hoses: check for any chafing.
• Check brake chamber mounting bolts and brackets.
• 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.
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.
Note: Oil change, filter change and chassis lubrication are no longer required at
the 3,000-mile vehicle break-in interval.
• Gear oils (transmission, rear axle carrier[s], front drive axle carrier, transfer
case, flywheel PTO)
• Engine oil
• Oil filters
• Fuel filters
• Coolant conditioner
Note: When checking oil levels, the vehicle must be parked on level ground, and
the units at normal operating temperature. Components must be filled to the correct
level. DO NOT OVERFILL.
Note: Oil and filter change intervals in this manual pertain to components built by
Mack Trucks, Inc. For information concerning oil and oil filter change intervals for
vendor components, refer to the specific vendor component service literature.
After the First 5000 Kilometers (3000 Miles) or Before 6400 Kilometers
(4000 Miles) or Before 3 to 4 Months
OPERATION 115
• 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).
C0029314
OPERATION 117
HOOD OPERATION
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.
118 OPERATION
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.
OPERATION 119
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
120 OPERATION
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.
OPERATION 121
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.
122 OPERATION
DOORS
C0029320
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 123
C0029322
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.
124 OPERATION
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.
C0029323
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.
OPERATION 127
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
C0029325
4. Align the transmitter case halves, then snap the case together.
5. Check the operation of the transmitter.
Troubleshooting
128 OPERATION
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.
Note: If more than four transmitters are programmed, the system will only retain
the last four transmitters programmed.
6. To exit Programming Mode, turn the ignition switch to the OFF position, or
simply wait 15 seconds. The LED will be off to confirm exit.
OPERATION 129
Feature Programming:
1. Turn the ignition switch to the ON position.
2. Access the keyless entry module, located behind the D-Panel.
3. Push the Program switch on the keyless entry module six times. The horn
will chirp six times, and the program LED on the module will be solid, to
indicate you are now in the Feature Programming Mode.
4. Press and release the transmitter button corresponding to the feature you
want to change.
Note: The horn chirps and LED pulses will indicate the new setting.
5. Press the transmitter button again to change the feature again. Keep
pressing the transmitter button until the module advances to your desired
setting.
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.
130 OPERATION
SEAT BELTS
DANGER
Seat belts should always be secured BEFORE the vehicle is set in motion.
Failure to use seat belts can result in SEVERE bodily injury or death. Unbelted
riders could be thrown into the windshield or other parts of the cab, or thrown
out of the cab entirely.
DANGER
Use the shoulder belt only on the shoulder that is closest to the vehicle door.
Never wear the shoulder portion of the belt under your arm or behind your back.
Improper use will increase your chances of injury during a collision.
DANGER
To prevent possible injury the belt must be positioned low over the pelvis, below
the abdomen. If the belt is buckled too high, it will apply force to the abdomen, not
the pelvic region, and could cause serious internal injuries during a sudden stop.
OPERATION 131
DANGER
Do NOT wear seat belt loosely. Do NOT use one belt for more than one person.
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.
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.
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.
OPERATION 133
Webbing — The webbing should show no signs of wear, fraying or holes, and
it should be reasonably free of dirt which could find its way into the retracting
mechanism.
Retractors — The retractors should function smoothly and maintain
an appropriate amount of tension. Loose webbing is an indicator that
maintenance is needed; it’s likely that a too-loose belt will fail to tighten
properly when necessary.
Seat Belt Mounting Components — The tethering should be free of wear
and debris; the webbing should show no signs of wear, fraying or holes; and
the metal components should be free of signs of damage, corrosion or rust.
DANGER
Seat belt assemblies must be replaced after an accident if they have been
subjected to loading by occupants (even if no damage is obvious), or if they have
been damaged by an accident (bent retractor, torn webbing, etc.). If there is any
question regarding belt or retractor condition, replace the appropriate part.
DANGER
Do NOT attempt to engage the Komfort Latch feature while the truck is in motion.
Engagement — Pull the webbing of the shoulder belt away from the upper
torso, pulling only as much slack as needed while still allowing the belt to exert
slight pressure against your chest and shoulder. (Maximum amount of slack
should not exceed one inch when measured from the chest to the belt.) While
holding the slack, lift the lever located on top of the Komfort Latch mechanism
upward to clamp the webbing in place.
Normal Release — To unfasten the seat belt, simply release the buckle and
give the shoulder belt a quick tug to release the Komfort Latch mechanism.
Allow the belt to retract into the retractor.
Emergency Release — In the event of an emergency, release the seat belt
buckle. It is not necessary to release the Komfort Latch in an emergency
situation.
DANGER
Excessive slack will reduce effectiveness of the seat belt, which could result in
personal injury and death. CAREFULLY follow the instructions for adjusting
the tension-relieving device.
OPERATION 135
DANGER
To avoid personal injury, DO NOT occupy the sleeper bunk unless the restraint
is completely attached.
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.
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.
136 OPERATION
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.
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.
138 OPERATION
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.
OPERATION 139
C0029328
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-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.
OPERATION 141
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.
C0029329
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.
Note: To increase the engine speed, press and hold the Accel switch until the desired
speed is attained, or press the accelerator pedal until the desired speed is attained
and then press and release the Set switch.
OPERATION 143
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.
144 OPERATION
WARNING
Operation of any vehicle on wet or slippery roads requires extreme caution.
Because the engine brake converts the engine to a retarding device, it should
NOT be used on wet or slippery roads if the vehicle has a single driving axle
or if it has tandem driving axles that are lightly loaded. Use of an engine
brake under these conditions can cause the vehicle to skid or a combination
vehicle to jackknife.
OPERATION 145
C0029330
To operate the vehicle without the engine brake active, leave the
dash-mounted switch in the OFF position.
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.
will again be activated. In order to disable the engine brake, simply return the
dash-mounted control switch to the OFF position.
DANGER
The engine brake should never be considered a substitute for the vehicle service
brakes. The service brakes should always be maintained in good working order,
and should always be viewed as the primary vehicle slowing system. Service
brakes are always used to bring the vehicle to a complete stop.
Note: Deactivating the cruise control function does not disable the engine brake.
C0029331
1. High 3. Off
2. Low
148 OPERATION
As grades and vehicle weight increase, it will be necessary to use the HIGH
position.
C0029332
1. High 3. Off
2. Low
Descending a Grade
DANGER
The MACK PowerLeash™ Engine Brake assists you in establishing faster
downhill descent speeds than in a similarly configured and loaded vehicle without
an engine brake; nevertheless, even with an engine brake, there are limits to the
maximum vehicle speed at which you can travel on downhill grades and still
keep your vehicle safely under control. Always approach these situations with
caution, and gain the experience necessary for each grade and driving condition
to determine the appropriate downhill descent speed.
For a certain vehicle and load condition, a "control speed" may be established
for a given descent. The control speed is the vehicle speed at which the
retarding forces of air drag, rolling resistance and engine brake power are
equally balanced by the natural force of gravity that causes the vehicle to
accelerate down the hill, resulting in a steady, controlled vehicle speed. The
additional vehicle slowing power offered by the MACK PowerLeash™ Engine
Brake allows the driver to descend the hill in a higher gear than normal (at a
faster control speed), without overspeeding the engine.
For example, consider that you are descending a grade with a specific vehicle
and an assumed total vehicle weight. You will find that without an engine
brake, you must descend this grade in third gear to maintain a steady 10 mph
at 2,000 engine rpm, without the need to apply the service brakes.
OPERATION 149
C0029333
Switch the MACK PowerLeash™ Engine Brake to the HIGH position, and now
it is possible to descend the same grade in sixth gear to maintain a steady
35 mph at 2,000 engine rpm.
CAUTION
The maximum allowable engine speed is listed on the warning label on the sun
visor. Do NOT exceed 2,300 rpm.
C0029334
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.
C0029335
1. High 3. Off
2. Low
Only if the vehicle demonstrates good control in the LOW position (again, only
in safe driving conditions) should you test in the HIGH position, if desired.
Return to the LOW position and proceed with caution if there is any sign of
loss vehicle control.
Note: Always monitor vehicle tractability in slippery road conditions, and make
adjustments to engine brake switch position and vehicle speed as necessary. Always
test the LOW power position setting before moving to the HIGH position.
Your MACK PowerLeash™ Engine Brake and ABS control systems are
designed to work together for optimized vehicle control. The engine brake
function may be modified or interrupted briefly in the event of pending wheel
lock.
CAUTION
Do not enable the MACK PowerLeash™ Engine Brake during bobtail operations,
or when operating on slippery roads with an empty or lightly loaded trailer.
152 OPERATION
BRAKE OPERATION
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.
OPERATION 153
DANGER
Automatic slack adjusters should not be manually adjusted in an effort to correct
excessive pushrod stroke, because this condition indicates that a problem exists
with the automatic adjuster, with the installation of the adjuster, or with related
foundation brake components, which manual adjustment will not fix. Manual
adjustment of automatic slack adjusters is a dangerous practice that could have
serious consequences, because it gives the operator a false sense of security
about the effectiveness of the brakes, which are likely to go out of adjustment
again soon.
Parking
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.
OPERATION 155
ABS Operation
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 155 for more
information.
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.
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.
OPERATION 157
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.
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.
158 OPERATION
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.
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.
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!
162 OPERATION
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.
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.
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.
164 OPERATION
DANGER
Before working on or inspecting a vehicle, set the parking brakes, place the
transmission in neutral and block the wheels. Failure to do so can result in
unexpected vehicle movement and can cause serious personal injury or death.
DANGER
To avoid potential fire hazard, do not service any part of the fuel system while
smoking or in the presence of flames, sparks or hot surfaces, or when working on
an operating engine. Failure to follow these precautions can result in fire. To
guard against burns from direct contact with hot fuel, wear adequate protective
clothing (face shield, heavy gloves and apron, etc.) when working on a hot engine.
WARNING
DO NOT work near the fan with the engine running. The engine fan can
engage at any time without warning. Anyone near the fan when it turns on
could be seriously injured. Before turning on the ignition, be sure that no
one is near the fan.
1. Unlock the hand primer pump by pushing the pump handle in and turning it
counterclockwise.
C0029336
C0029337
Note: When the fuel system is empty, 200 or more pump strokes may be needed
to properly prime the system.
Note: There are NO bleed nipples to be opened in order to prime the fuel system.
3. Lock the hand primer pump by retracting it into the housing and turning
it clockwise.
4. Start the engine and run it at an increased idle speed for approximately 5
minutes to remove any remaining air in the system.
5. Check the fuel system for leaks.
Note: If the engine does not start following this procedure, contact your local MACK
dealer.
166 OPERATION
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.
Note: Many accessories are available for cold weather operations. Refer to the
Maintenance and Lubrication Manual (TS494) 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.
OPERATION 167
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.
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.
OPERATION 169
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.
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.
C0029338
Winterfronts
A winterfront, although not recommended, may be used during cold weather,
with sustained temperatures below -25°C (-13°F), to aid the engine in reaching
and maintaining engine coolant temperatures within the normal operating
range.
CAUTION
Use a winterfront designed for the specific chassis. Restricted air flow through the
charge air cooler can cause higher exhaust temperatures, power loss, excessive fan
usage, reduced fuel economy and possible engine or charge air cooler damage.
The use of any other type of device, such as a radiator cover, cardboard or similar
material, is not approved by Mack Trucks, Inc.
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.
172 OPERATION
Refer to the following chart for suggested temperature ranges concerning the
use of various cold-weather accessories.
Expected
Sustained
Coldest
Ambient
Temperature Inside/Outside
Range Winterfronts Belly Tarp Air
4°C (40°F) Prohibited Available
0°C (32°F)
-7°C (20°F) Prohibited Available Suggested
-12°C (10°F) Suggested
-18°C (0°F)
-23°C (-10°F)
-25°C (-13°F) Recommended
Can be Used Recommended
-35°C (-30°F)
-40°C (-40°F)
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.
C0029339
COUPLING A TRAILER
1. Position the tractor directly in front of the trailer.
2. Back the trailer slowly until the fifth wheel just contacts the trailer plate.
3. Place the transmission in neutral and apply the parking brakes.
4. Connect the trailer glad hands and electrical connector.
CAUTION
Make sure the trailer air lines and the trailer electrical cord are properly supported
so they will not be pinched or caught while the tractor is being backed under the
trailer.
5. Check that the fifth wheel height matches the height of the underside of
the trailer. If the trailer is too high, use the landing gear to lower the trailer
until fifth wheel and trailer height match. If the vehicle is equipped with an air
suspension and the trailer is too low, use the air suspension control switch
to exhaust air from the suspension air bags until fifth wheel and trailer height
match.
CAUTION
Failure to match fifth wheel height with trailer height will result in the trailer being
improperly connected.
6. Back under the trailer slowly until the trailer king pin engages. Back slowly
to avoid hitting the king pin too hard, and stop as soon as the king pin is
locked into the fifth wheel.
7. If equipped with an air suspension, use the air suspension control switch
to reinflate the suspension air bags.
8. Raise the trailer landing gear slightly off the ground.
9. With the trailer parking brakes applied, pull the tractor ahead slightly to
ensure that the trailer is locked onto the tractor.
10. Push the trailer air supply valve (red octagonal knob) in to supply the trailer
system with air pressure. With the air system at normal operating pressure,
check the trailer air brake system for excessive leakage and proper operation.
OPERATION 175
11. Inspect the coupling to ensure the trailer is properly connected. Make
sure there is no space between the fifth wheel and the trailer plate and that
the fifth wheel jaws have closed around the shank of the king pin. Check
that the locking lever is in the "lock" position and make sure the safety latch
is in position over the locking lever.
12. After ensuring that the trailer is properly connected, raise the landing
gear to its maximum height.
13. If wheel chocks were placed at the trailer wheels, remove the chocks
and store.
CAUTION
If equipped with an air suspension, do NOT operate the vehicle with the suspension
air bags deflated. Always reinflate the suspension air bags after coupling or
uncoupling a trailer.
176 OPERATION
UNCOUPLING A TRAILER
1. Park the tractor/trailer combination on a level surface. Make sure the
parking surface will support the weight of the trailer, and make sure that the
tractor is lined up straight with the trailer. Pulling out from under a trailer at an
angle may damage the landing gear.
2. Pull the trailer air supply valve (red octagonal knob) out to apply the trailer
parking brakes.
3. Back the tractor slightly to ease pressure on the fifth wheel jaws. Apply
the tractor parking brakes while still backing against the king pin so the
combination will be held with pressure off the fifth wheel jaws.
4. Block the trailer wheels to prevent the trailer from moving.
5. Lower the trailer landing gear until the gear makes firm contact with the
ground.
6. Disconnect the glad hands and the trailer electrical connector. Connect the
glad hands to the dummy couplers at the back of the tractor and install the
trailer electrical connector into the receptacle provided at the back of the cab.
CAUTION
Make sure the trailer air lines and electrical cord are properly suspended so they
will not become tangled or damaged while the tractor is being driven.
WARNING
Keep legs and feet clear of the tractor rear wheels to avoid serious injury
should the vehicle move when the fifth wheel is unlocked.
12. Inspect the parked trailer to make sure the ground is supporting the trailer
and the landing gear is not damaged.
13. If equipped with an air suspension, use the air suspension control switch
to reinflate the suspension air bags.
14. Release the parking brakes and drive the tractor forward until the tractor
is clear of the trailer.
CAUTION
If equipped with an air suspension, do NOT operate the vehicle with the suspension
air bags deflated. Always reinflate the suspension air bags after coupling or
uncoupling a trailer.
178 OPERATION
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.
OPERATION 179
CAUTION
Do not permit a load to drive the engine above governed speed. When descending
steep grades, use lower gears and watch the tachometer. Overspeeding will cause
severe drivetrain damage and eventually destroy the engine.
CAUTION
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.
180 OPERATION
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.
OPERATION 181
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.
C0029340
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.
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 185
PTO Classification
Rear-mounted PTO units, for MACK transmissions, are categorized according
to operation.
Intermittent Service — The PTO unit is operated, under load, for less than
seven minutes and then allowed to cool before it is operated again.
Note: If a PTO unit is operated for less than seven minutes but is "not" allowed to
cool down before operating again, it is considered in Continuous Service.
Continuous Service — The PTO unit is operated, under load, for seven
minutes or more.
Note: Rear-mounted PTO units operating under the Continuous Service guideline
must not be run at more than 70% of the PTO output-rated torque/horsepower.
CAUTION
The maximum safe operating oil temperature for MACK transmissions is
121°C (250°F) for mineral-based oil, and 148°C (300°F) for synthetic-based
oil. Continued operation with oil above this temperature will result in rapid
deterioration of the oil’s lubricating properties and is NOT recommended.
CAUTION
To avoid transmission damage, the vehicle must be completely stopped before being
shifted from REVERSE to any forward speed (and vice versa).
CAUTION
Never coast with the transmission in neutral. Never coast with the clutch depressed.
C0029341
Gear Ratio
1 7.50
2 4.08
3 2.41
4 1.50
5 1.00
6 0.71
Reverse 8.84
188 OPERATION
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.
C0029342
Ratios
Gear (Main Box) LO Range Hi Range
First Lo 17.77
Second Lo 10.94
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 18.36
Reverse Hi 6.79
190 OPERATION
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.
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 191
C0029343
Ratios
Gear (Main Box) LO Range Direct Range Reverse
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
192 OPERATION
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.
C0029344
OPERATION 193
Ratios
Gear (Main Box) LO Range Hi Range
First Lo 25.21
Second Lo 15.52
Third Lo 9.73
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 25.67
Reverse Hi 6.79
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.
194 OPERATION
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 195
C0029345
Ratios
Gear (Main Box) LO Range Direct Range Reverse
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
196 OPERATION
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 197
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
198 OPERATION
Preferred Methods for Engaging T309 "Eighth" Gear (or any Hi-Range
Gear) for Output Shaft Driven Power Take-Off (PTO) Operation
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.
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.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
202 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
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 203
CAUTION
When the truck is stationary, do NOT shift into HI range and then start moving the
truck. Damage to the synchronizer may result.
C0029348
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.
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.
206 OPERATION
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.
To upshift from LO-split to HI-split (in the same gear), accelerate the engine
to governed speed, move the splitter switch to HI (preselect), depress the
clutch and back off the accelerator pedal. Reapply the accelerator and engage
the clutch when the audible shift is heard, or when the engine speed falls by
approximately 200 rpm. Depressing the clutch may not be necessary to break
the driveline torque, but this will vary with road and load conditions.
To upshift from a HI-split gear to the next higher gears LO-split (in HI range),
accelerate the engine to governed speed, then move the splitter switch to LO
as you move the shift lever through NEUTRAL to the next higher gear. Note
that the splitter switch must not be actuated down to the LO position until
the main box is in NEUTRAL.
Downshift — Shift from eighth HI-split to eighth LO-split, then seventh
HI-split, seventh LO-split and so on (double-clutching between the gears),
until you reach fifth LO-split.
While in fifth gear LO-split, flip the range selector down to LO range (preselect),
then move the shift lever through NEUTRAL to fourth gear (double-clutch and
use the throttle in the normal manner between gears). As the shift lever moves
through NEUTRAL, the range shift to LO will be completed. You are now in
fourth gear LO-split (LO range). Continue downshifting, using the shift lever in
the normal manner until you reach LO speed gear (LO range, LO-split).
To downshift from HI-split to LO-split (in the same gear) as engine speed falls,
move the splitter to LO (preselect), then release and reapply the accelerator
pedal. An audible shift completion should be heard.
To downshift from a LO-split gear to the next lower gears HI-split (in HI range)
as engine speed falls, move the splitter switch to HI as you move the shift
lever through NEUTRAL to the next lower gear. Note that the splitter switch
must not be actuated up to the HI position until the main box is in NEUTRAL.
Remember to double-clutch between gears.
T313 and T313L Reverse — Reverse can be used in LO range only.
T313LR Reverse — Reverse can be used in LO and HI range.
To make a range shift in reverse, bring the truck to a complete stop. Flip the
range selector to the range desired (preselect). Move the shift lever out of
reverse through NEUTRAL, and then back into reverse again. As the lever
moves through NEUTRAL, the range shift will be completed.
CAUTION
To avoid transmission damage, do NOT change range while moving in REVERSE.
208 OPERATION
C0029349
OPERATION 209
Gear Ratios
(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
210 OPERATION
Note: The transmission MUST be in LO range and LO-split at all times during PTO
operation.
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.
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 213
C0029350
214 OPERATION
Gear Ratios
(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
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
OPERATION 215
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.
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 217
C0029351
218 OPERATION
Gear Ratios
(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 219
Note: The transmission MUST be in LO range and LO-split at all times during 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 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 221
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.
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 223
C0029352
224 OPERATION
Gear Ratios
(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 225
Note: The transmission MUST be in LO range and LO-split at all times during 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 227
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.
228 OPERATION
AXLES
CAUTION
The maximum safe operating oil temperature for a MACK rear axle is 121°C
(250°F) for mineral-based oil, and 148°C (300°F) for synthetic-based oil.
Continued operation with oil above this temperature will result in rapid
deterioration of the oil’s lubricating properties and is NOT recommended.
OPERATION 229
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.
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.
230 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 231
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.
2. MACK-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, Inc., 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 233
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 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.
234 OPERATION
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.
236 OPERATION
W2029933
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 237
Safety Information
Mack utilizes the use of a Diesel
Particulate Filter (DPF) and Selective DANGER
Catalytic Reduction (SCR) to meet
EPA2010 emissions. The system is Exhaust gases and components can
designed to require very little driver be at extremely high temperatures
interface to maintain correct operation. during regeneration. When parking the
The technology utilizes a passive vehicle, keep away from any flammable
regeneration; requiring no fuel to be materials, vapors, or structures.
injected to clean the DPF. In EPA2007 an
active regeneration (fuel was injected) was
required to clean out the DPF producing DANGER
very high exhaust outlet temperatures.
Certain vocational duty cycles will The temperature of the exhaust system
require the use of fuel and/or a parked components during the regeneration
regeneration to clean out built-up soot in process can exceed 350 degrees C
the particulate filter. Exhaust temperatures (660 F). The exhaust gas leaving
will increase during a parked regeneration. the system can reach 505 degrees C
When parking the vehicle to perform a (930 F). Various factors (including
parked regeneration keep away from any ambient temperature and duration of the
flammable materials, vapors or structures. 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.
238 OPERATION
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
OPERATION 239
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.
240 OPERATION
The Mack SCR system is simple and effective, with few components. It consists
of a Aftertreatment DEF tank positioned near the standard diesel tank, plus a
Aftertreatment DEF pump, Aftertreatment DEF Dosing unit and SCR catalyst.
The advantage of using DEF is that it enables the engine to use less EGR -- and
higher oxygen levels -- for better combustion, while meeting the EPA 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 engine.
W2055490
W2055491
W2055492
W2055493
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.
242 OPERATION
W3036787
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.
DEF will be available in 2.5-gallon containers, 55-gallon drums, 275 gallon IBC and
in bulk storage for fleet locations, truck stops and dealerships. All major truck stops,
dealers and distributors will carry DEF.
DEF will freezes below –11 degrees C (12 F). DEF needs to be protected from
extended periods of severe cold. For more information on DEF and availability
please visit the website: www.Mackscr.com or please contact Mack One-Call at
1–800–866–1177.
OPERATION 245
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.
W2030326
OPERATION 247
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
• NOX Sensors
The ACM is a stand alone module. Depending on your configuration it may be
mounted as part of the DEF tank (as shown above) or on a bracket near the DEF tank.
248 OPERATION
C0029148
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 249
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 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 EPA2010.
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.
250 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 251
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 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.
252 OPERATION
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 253
Instrument Cluster
The aftertreatment icons are located in the instrument cluster per the following images.
W3031621
regeneration is needed.
High Exhaust System Temperature
(HEST) Icon
W2029416
W3007445
Aftertreatment DEF Tank Low Level
Aftertreatment DPF Regeneration Indicator (DEF)
Required Icon The Aftertreatment DEF Tank Low Level
The High Exhaust System Temperature Indicator icon illuminates when the fluid
icon illuminates when a parked level is low. It also Flashes when the level
Aftertreatment DPF Regeneration becomes critically low.
Required is initiated. It also indicates high
W3031200
MIL Lamp
• MIL indicates government Regulation • Lamp may remain active after repair
On Board Diagnostics (OBD) faults until system confirms repair
256 OPERATION
W2029415
W3031623
W3031623
Note: Vehicle has to be stationary before 8 km/h (5 mph RSL) becomes active.
258 OPERATION
Exit conditions for DEF Quality "5 mph road speed limit" Inducement:
First Restart: Return to 25% torque reduction until proper DEF quality evaluation. If
poor DEF quality is detected during the next monitoring cycle then the 5 mph limit is
resumed after vehicle is stationary for 20 minutes. After the second restart a Service
Tool is required to exit the 8 km/h (5 mph) RSL.
W3031623
W3031623
W3031623
Note: Operator can not override the 5 Note: Vehicle has to be stationary before
mph road speed limit and that 5mph road 8 km/h (5 mph RSL) becomes active.
speed limit.
260 OPERATION
MAINTENANCE INTRODUCTION
Preventive maintenance is vital to the life of your new vehicle. This section of
the Operator’s Handbook covers items of importance concerning the proper
care of MACK vehicles. A well-run maintenance and lubrication program is
the best way to ensure a long life of productive operation.
The operator plays an important role in the proper care of this equipment. By
performing daily checks and observing the equipment while in operation, minor
defects can be caught and corrected before they become major problems.
Make sure any problems are corrected before putting the equipment into
operation.
If you have any questions concerning the proper care, maintenance and
lubrication of your vehicle, or if you need help in developing a preventive
maintenance program, contact the service manager at the local MACK Sales,
Parts and Service Center.
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.
MAINTENANCE AND LUBRICATION 263
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.)
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.
264 MAINTENANCE AND LUBRICATION
CAUTION
Proper care of the paint finish is an important part of the durability. Chemicals
used to wash the paint should be of neutral pH with a range of between 6 and 8.
Detergents containing butyl cellosolve or potassium hydroxide should not be used.
Note: Vehicles should be washed only in special wash bays to protect the environment
from cleaning agent contamination.
DANGER
Vehicle cleaning products must be handled carefully, as these products may be
poisonous. Keep all cleaning products out of the reach of children.
WARNING
Do not clean the underside of the fenders, cab, chassis, etc., without protecting
the hands and arms, as injuries may result when scraping against sharp edges.
CAUTION
For chassis used in concrete operations, do not use muriatic acid or similar types
of products to clean concrete from the cab or frame surfaces. Use of these types of
products will damage the paint finish and void the vehicle warranty. Mack Trucks,
Inc. has approved EL-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
MAINTENANCE AND LUBRICATION 265
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.
266 MAINTENANCE AND LUBRICATION
Cab Interior
• For cleaning vinyl upholstery and lining: wipe with a soft cloth, using a good
commercial upholstery cleaner. Do not use acetone, lacquer thinner, etc.
• For cleaning fabric upholstery: use an upholstery shampoo specially
designed for this purpose. Follow the directions on the manufacturer’s label.
Waxing
• Always use waxes and polishes that are non-abrasive. Do not use waxes or
polishes that contain silicone.
• When water does not form small drops and roll off clean paint, apply a coat
of good hard wax.
• Even if a liquid wax solution is used on a regular basis, it is advisable to
protect the finish with a hard wax at least twice a year.
• Your truck may have a basecoat plus clearcoat. Use a basecoat/clearcoat
wax on your paint finish.
Polishing
Polish your truck only if the paint has lost its shine and the gloss cannot be
brought back with wax. It is recommended to have a professional polish your
truck to avoid swirl marks or damage to the painted surface. Mequiar’s® has a
complete line of waxes, polishes and other cleaning and care products that
are approved for use on MACK cabs, hoods and sleeper surfaces.
Winter Warnings
• If you rinse your vehicle with a hose, avoid direct water into lock cylinders.
You may experience freezing of the lock mechanism.
• Test brakes after each vehicle wash. Moisture and ice on brakes can affect
braking efficiency.
A well kept vehicle can look like new after many years of service. Proper
care and maintenance can help you keep your vehicle’s beauty and value.
You can get an assortment of Mack Trucks approved cleaning products from
your local Mack dealer.
MAINTENANCE AND LUBRICATION 267
TOWING
Tow pins, hooks, eyes, etc., are located in or behind the front bumper. These
devices meet the recommendations for towing set forth by the Technology and
Maintenance Council (TMC) of the American Trucking Association and can be
used for towing a disabled vehicle from the immediate location.
CAUTION
Do NOT lift and tow any vehicle by tow pins, hooks, eyes, etc. If the vehicle is mired
in heavy mud, snow, etc., use a suitable sling-type towing arrangement.
Note: Tow pins, hooks, eyes, etc., are NOT intended for use as long-term towing
devices.
CAUTION
Failure to disconnect the driveshaft, remove the drive axle shaft(s) or lift the drive
wheels off the ground before towing or pushing the vehicle, can cause serious
transmission damage.
DANGER
If the drive shaft has been removed for towing, DO NOT reuse bearing retainer
bolts or stamped strap bolts, or stamped straps. Reuse of bearing retainer bolts
or stamped strap bolts, or stamped straps can cause driveline failure, which can
result in separation of the driveline from the vehicle. A separated driveline can
result in property damage, serious personal injury or death.
C0029420
268 MAINTENANCE AND LUBRICATION
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 269
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
270 MAINTENANCE AND LUBRICATION
C0029423
For additional information about power steering, refer to the Maintenance and
Lubrication Manual (TS494).
MAINTENANCE AND LUBRICATION 271
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
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.
MAINTENANCE AND LUBRICATION 273
CAUTION
Ultra Low Sulfur Diesel (ULSD) fuel with a maximum sulfur content of 15 ppm
must be used in order to meet Euro4 engine emission requirements.
Using otherwise approved diesel fuels with a maximum sulfur content greater than
500 ppm may shorten engine life and void the engine warranty.
Air is always present inside the fuel tanks, entering mainly through the tank
ventilation. With the air being heated and cooled, condensation is formed and
water is mixed in the fuel. To avoid condensation when the vehicle is parked
for longer periods, fill the tanks up to 95% of capacity. Do not fill more than
that, as the fuel needs to have room for expansion during the heat of the day.
BioDiesel
Soy Methyl Ester (SME or SOME) BioDiesel fuel in blends up to a B5
concentration (5% blend) is approved by Mack Trucks, Inc.
Note: MACK Engines are certified to comply with U.S. EPA and California Air
Resources Board (CARB) emissions standards based on the use of reference test
fuels commonly available in the United States and specified in this manual. Use of
alternative fuels, including BioDiesel, may affect engine emissions. Mack Trucks,
Inc. does not warrant, and is not responsible for ensuring that the engines will comply
with U.S. EPA and CARB emissions standards.
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.
WARNING
Turn the cooling system pressure cap counterclockwise slowly. After the
pressure has completely dissipated, continue turning to remove the cap.
Your MACK 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.
MAINTENANCE AND LUBRICATION 275
C0029425
1. Expansion Tank
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.
276 MAINTENANCE AND LUBRICATION
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: 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.
CAUTION
Do NOT use coolant solutions which contain anti-leak additives in trucks equipped
with coolant filters or conditioners.
CAUTION
Do NOT use soluble oil-type coolants in any MACK cooling system.
MAINTENANCE AND LUBRICATION 277
C0029647
C0029426
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.
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 (TS494) 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 281
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
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.
282 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.
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 (TS494) for more information.
CAUTION
For important tire information (i.e., high speed limits, inflation pressures, etc.),
consult the product information available through the specific tire manufacturer.
BATTERY
CAUTION
To avoid damage to sensitive electronic equipment, disconnect ALL battery cables
and harnesses to electronic control units before welding. Do NOT disconnect
batteries while engine is running.
Jump-Starting Engine
If you encounter a situation in which it is necessary to jump-start an engine,
use the following procedures.
WARNING
Batteries which are to be linked together must be of the same voltage (12 to
12, 24 to 24). Take care to observe proper polarity when connecting batteries.
Batteries produce explosive gases. Keep sparks, flames, cigarettes, etc., away
from batteries at all times. Protect your eyes by wearing safety goggles. Be
sure vehicles are NOT touching each other.
CAUTION
To avoid damaging any electronic controllers when jump-starting a V-MAC vehicle,
always turn the ignition switch OFF before connecting the batteries.
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.
MAINTENANCE AND LUBRICATION 285
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.
286 MAINTENANCE AND LUBRICATION
ELECTRICAL
C0029433
MAINTENANCE AND LUBRICATION 287
C0029434
1. Front 2. Back
288 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.)
MAINTENANCE AND LUBRICATION 289
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.
290 MAINTENANCE AND LUBRICATION
CAUTION
The electrical systems on all MACK 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.
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.
294 MAINTENANCE AND LUBRICATION
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.
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 (TS494).
296 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
297 METRIC CONVERSIONS