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Mack TerraPro LEU 2010 Operator's Handbook Manual

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Mack
TerraPro
®
(LEU Series)
21394654
© Mack Trucks, Inc. 2010
Printed in U.S.A.
Series
TM
21394654
April 2010
Mack
TerraPro
Series
®
TM
(LEU Series)

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Summary of Contents for Mack TerraPro LEU 2010

  • Page 1 Mack TerraPro Series Mack TerraPro Series ® ® (LEU Series) (LEU Series) 21394654 21394654 © Mack Trucks, Inc. 2010 April 2010 Printed in U.S.A.
  • Page 3 Foreword This manual contains information concerning the operation and function of the Mack Link System. The information in this manual applies to vehicles built April 2010 and later. Please keep this manual in the vehicle at all times. Note: Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle.

  • Page 4: Table Of Contents

    EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA....14 Emissions Control System Warranty ...............16 SERVICE LITERATURE ....................20 MACK Class 8 –Components Service Manual ............20 MACK Class 8 – Custom Collated Service Manual on CD ........20 CUSTOMER SERVICE ....................21 Call 1-800-866-1177 for MACK OneCall™ ............21 Questions and Complaints ..................21 Addresses .........................22...
  • Page 5 Cab Door Seals and Key Locks ................45 Outside Mirror Heater....................45 Air Horn Snow Shield....................46 Fire Extinguisher (Optional) ..................46 INSTRUMENTS AND CONTROLS ................47 CAB INTERIOR — LEFT ..................47 CAB INTERIOR — RIGHT ..................48 INSTRUMENT PANEL ....................49 Tell-Tales........................49 Panel Arrangement....................50 INSTRUMENT PANEL GAUGE LAYOUT ..............51 Panels A, B, C and D ....................52 Panel E ........................53 Panel F ........................54...
  • Page 6 MACK POWERLEASH™ ENGINE BRAKE (IF EQUIPPED)......116 Engine Brake Switch....................117 How the Engine Brake is Activated...............117 Cruise Control with the MACK PowerLeash™ Engine Brake ......118 ON THE ROAD WITH THE MACK POWERLEASH™ ENGINE BRAKE ..119 Over Flat Terrain....................119 Descending a Grade ....................120 On Slippery Road Surfaces..................122 BRAKE OPERATION....................124...
  • Page 7 Status Lights ......................148 Transmission Module Location ................149 AXLES........................150 Rear Axles Other Than MACK ................150 MACK Rear Axles....................150 Engaging the Power Divider Lockout..............151 Extended Idling and Aftertreatment System Conditioning ........154 Mack, US10 Emissions Solution .................155 DIESEL PARTICULATE FILTERS .................155 Exhaust Aftertreatment System .................158 Safety Information ....................159...
  • Page 8 BioDiesel........................192 B5 Approval For MACK US 2010 Certified Products ..........192 COOLING SYSTEM....................194 Coolant Level Check....................194 Draining the Cooling System.................195 Refilling the Cooling System .................195 Protecting the Cooling System ................196 Cooling System Maintenance ................197 Accessory Drive Belt Routing ................198 HEADLIGHTS ......................199 Bulb Replacement....................199...
  • Page 10 Safety Information IMPORTANT: Before driving this DANGER vehicle, be certain that you have read and that you fully understand each and Danger indicates an unsafe practice that every step of the driving and handling could result in serious personal injury information in this manual.

  • Page 12: Introduction 1

    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®...

  • Page 13: About This Handbook

    2 INTRODUCTION About This Handbook This handbook is referred to as the Mack® TerraPro™ LEU Series Operator’s Handbook. It covers all Mack® TerraPro™ LEU models. Its identification number is 21394654. Keep this handbook with the vehicle at all times to ensure that each owner and/or operator will have access to all pertinent information relating to the operation and handling of this vehicle.

  • Page 14: The Vehicle

    Mack Trucks, Inc. Service Publications Department. Contact your local MACK dealer for details. WARNING Never cut into the V-MAC system wire harness to power additional equipment. If such equipment is to be installed, contact your MACK dealer for assistance.

  • Page 15: Component Identification

    4 INTRODUCTION COMPONENT IDENTIFICATION Locate the following serial numbers and write them in the boxes provided next to each illustration. VIN Locations The Vehicle Identification Number (VIN) is displayed in two locations (a frame rail stamping and a label). The 17-digit VIN must be identical in both locations. The VIN frame stamping is located on the right outside frame rail and the left inside frame rail.

  • Page 16: Engine Identification

    INTRODUCTION 5 Engine Identification On the MACK MP engines, the engine serial number is stamped on the left side of the engine block, below the inlet manifold. C0028943...

  • Page 17: Engine Information Plate

    Engine Information Plate In compliance with Federal and California emission requirements, an engine information label is affixed to all MACK diesel engines. This label, which is located on the cylinder head cover at the front of the engine, gives basic engine identification information (engine model, serial number, etc.), advertised horsepower at rated speed, emissions regulations to which the engine conforms and inlet and exhaust valve lash settings.

  • Page 18: Clean Idle Engines

    INTRODUCTION 7 Clean Idle Engines The California Air Resources Board (ARB) requires that 2008 and later model year vehicles be equipped with engines having tamper-resistant software which limits the time at which the engine can idle at speeds above low idle (550–700 rpm).

  • Page 19: Transmission Identification

    The Allison RDS and HS transmission identification plate is located on the rear right side of the main case, near the lower end. C0029555 The MACK carrier assembly serial number is located on the front right side of the housing. C0028950 The Eaton®...
  • Page 20 INTRODUCTION 9 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.

  • Page 21: Warranty Information

    Air Brake System The MACK Standard Vehicle Warranty applies to the air brake system, as set forth in the Warranty, but only if the air brake system has not been subjected to unauthorized additions, deletions or modifications. If any such unauthorized additions, deletions or modifications are performed, Mack Trucks, Inc.

  • Page 22: Emissions Control System Warranty

    The repair or replacement of defective Control Systems on each new Mack parts will be made without charge for diesel engine in a new Mack Truck to the cost of parts and if repairs are made comply with all United States Federal at an authorized Mack Trucks, Inc.
  • Page 23 12 INTRODUCTION • 5 Engine and Vehicle Wire harness ( Aftertreatment DPF Intake repair to circuits related to Emissions Temperature Sensor • Warrantable Components ) Aftertreatment DPF Outlet 6 Exhaust Gas Recirculation (EGR) Temperature Sensor • Mixer Aftertreatment DPF Differential Pressure Sensor 7 EGR Cooler •...

  • Page 24: Engine Gaseous Emissions Control System Warranty

    Note: In response to customer requests, Normal maintenance, such as cleaning Mack Trucks, Inc. may build vehicles with ash from the filter at regular maintenance engines supplied by other manufacturers. intervals and cleaning the aftertreatment...

  • Page 25: Federal Emission Requirements

    EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA The California Air Resources Board and system, turbocharger assembly, electronic Mack Trucks, Inc. are pleased to explain control module and other emission-related the California emission control system assemblies. warranty on your new motor vehicle Where a warrantable condition exists, engine.
  • Page 26 Systems on each new MACK diesel manual. Mack Trucks, Inc. recommends engine in a new MACK truck to comply that you retain all receipts covering with all State of California emissions maintenance of your vehicle, but Mack regulations applicable at the time of Trucks, Inc.

  • Page 27: Emissions Control System Warranty

    16 INTRODUCTION THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE, EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Emissions Control System Warranty The following engine components are covered by the supplemental emissions control system warranty policy as required by the California code of regulations.
  • Page 28 INTRODUCTION 17 • • Aftertreatment DPF Fuel Control Aftertreatment Selective Catalytic Valve Reduction (SCR) Catalyst • • Aftertreatment DPF Ignition Aftertreatment Diesel Exhaust Fluid Electrode (DEF) Pump • • Nozzle Aftertreatment DEF Dosing • Absolute Pressure Sensor Engine Exhaust Gas Temperature •...
  • Page 29 Use of replacement parts which are not the In an emergency, where an authorized equivalent of MACK parts may impair the MACK facility is not available, repairs effectiveness of emission control systems. may be performed at any available service If other than MACK parts are used, the...
  • Page 30 Damage resulting from accident, acts parts are warranted by their manufacturer of nature or other events beyond the to be the equivalent of MACK parts control of Mack Trucks, Inc. • in performance and durability. MACK...

  • Page 31: 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.

  • Page 32: Customer Service

    Your satisfaction is our most important concern. If questions or complaints arise, first discuss the matter with the service manager at the MACK facility involved. If you are not satisfied with the service manager’s response, contact the branch manager, principal or general manager of the distributorship.

  • Page 33: Addresses

    22 INTRODUCTION Addresses The addresses, telephone and fax numbers of the Mack Trucks, Inc. regional offices are: United States Northeast Region – 7900 National Service Road., Mail: P.O. Box 26259, Greensboro NC 27402 , TEL: (336) 291-9001 Southeast Region – 6768 Southlake Parkway, Morrow, GA 30260, TEL: (770) 960-0511, FAX: (770) 960-0593 Central Region –900 S.
  • Page 34 Description of unresolved service complaint or inquiry • Summary of action taken to date (by the dealer and the regional service office) • Names of individuals (if known) contacted at the dealer and the Mack Trucks, Inc. regional service office.

  • Page 35: Reporting Safety Defects

    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.

  • Page 36: Event Data Recording Devices

    INTRODUCTION 25 EVENT DATA RECORDING DEVICES Your Mack vehicle is equipped with a device generally referred to as an "event data recorder" or "EDR." Please note that while the term "event data recorder" is typically used throughout the motor vehicle industry, not every EDR is the same;...

  • Page 37: 26 Safety Information

    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.
  • Page 38 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.

  • Page 39: Certification Labels

    In compliance with NHTSA regulations, your Mack® vehicle has a safety certification label affixed in one of the NHTSA locations listed above. This label may be either an Incomplete Vehicle and/or Completed Vehicle label.
  • Page 40 SAFETY INFORMATION 29 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.

  • Page 41: Advisory Labels

    Mack® TerraPro™ LEU. (Your vehicle may not contain all of the labels illustrated in this handbook.) These labels are for your benefit.
  • Page 42 SAFETY INFORMATION 31 C0029557...
  • Page 43 32 SAFETY INFORMATION C0029558...
  • Page 44 SAFETY INFORMATION 33 C0029559...
  • Page 45 34 SAFETY INFORMATION Labels Found on Driver-Side Sun Visor C0029560...
  • Page 46 SAFETY INFORMATION 35 Labels Found on Cowl (Near Ashtray) C0029561...
  • Page 47 36 SAFETY INFORMATION Labels Found on Instrument Panel C0029017 C0029562...
  • Page 48 SAFETY INFORMATION 37 Eaton Controlled Traction Differential Label C0029020 Labels Found on Fuel Tank C0029021...
  • Page 49 38 SAFETY INFORMATION Back Up Alarm (Optional) Your chassis may be equipped with an optional back up alarm. If so, the following label will appear inside the cab. C0029022 C0029563...

  • Page 50: Cab Entry/Exit

    SAFETY INFORMATION 39 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.
  • Page 51 40 SAFETY INFORMATION 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.

  • Page 52: Driver Side

    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 one hand and grab the inside handhold with the other hand.
  • Page 53 42 SAFETY INFORMATION C0029564...

  • Page 54: Passenger Side

    SAFETY INFORMATION 43 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 Grab the handhold with one hand, and place the other hand on the steering wheel.

  • Page 55: Safety Tips For Cold Weather Operation

    44 SAFETY INFORMATION SAFETY TIPS FOR COLD WEATHER OPERATION Driver Visibility Poor driver visibility is not only annoying, but extremely unsafe under any circumstance. Without proper maintenance of visibility-related components, adverse weather conditions such as rain, snow and frost can seriously reduce visibility.

  • Page 56: Cab Door Seals And Key Locks

    SAFETY INFORMATION 45 • 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.

  • Page 57: Air Horn Snow Shield

    46 SAFETY INFORMATION Air Horn Snow Shield Installation of an air horn snow shield is recommended to prevent snow from clogging the air horn bell (maintaining maximum sound output). C0029133 Fire Extinguisher (Optional) Your vehicle may be equipped with a fire extinguisher which is located inside your cab.

  • Page 58: Instruments And Controls 47

    INSTRUMENTS AND CONTROLS 47 CAB INTERIOR — LEFT C0029566 3. Foot Pedals 1. Turn Signal, Hazard Switch and HI/LO Beam 2. Instrument Panels...

  • Page 59: Cab Interior - Right

    48 INSTRUMENTS AND CONTROLS CAB INTERIOR — RIGHT C0029567 1. Instrument Panels 3. Foot Pedals 2. Work Brake 4. Turn Signal, Hazard Switch and HI/LO Beam...

  • Page 60: Instrument Panel

    INSTRUMENTS AND CONTROLS 49 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.

  • Page 61: Panel Arrangement

    50 INSTRUMENTS AND CONTROLS 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.

  • Page 62: Instrument Panel Gauge Layout

    INSTRUMENTS AND CONTROLS 51 INSTRUMENT PANEL GAUGE LAYOUT W3056176...

  • Page 63: Panels A, B, C And D

    52 INSTRUMENTS AND CONTROLS Panels A, B, C and D W3056177 1. Coolant Temperature Gauge 8. DEF Gauge/Fuel Gauge 2. Tachometer 9. Air Pressure Gauge 3. Oil Pressure Gauge 10. Parking Brake Valve 4. Warning/Indicator Lamp Panel 11. Transmission Oil Temperature Gauge 12.

  • Page 64: Panel E

    INSTRUMENTS AND CONTROLS 53 Panel E C0029589 15. CB Radio Auxiliary Hookup 25. Auxiliary Switch — Body Function 16. DPF Smart Switch (If Equipped) 26. Light Control Panel 17. Inter-Axle Power Divider Lockout 27. Combination Starter and Electrical Switch (If Equipped) Switch 18.

  • Page 65: Panel F

    3. Oil Pressure Gauge — Indicates engine oil pressure. The normal operating oil pressure for a MACK MP7 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).
  • Page 66 INSTRUMENTS AND CONTROLS 55 4. Warning/Indicator Lamp Panel – Items listed below from left to right and top to bottom. W3056178 Detail of Warning/Indicator Light Panel – LH • Optional Tell-Tales • Malfunction Indicator lamp (MIL) — MIL indicates government Regulation On Board Diagnostics (OBD) faults.
  • Page 67 56 INSTRUMENTS AND CONTROLS • Optional Tell-Tales • HEST Indicator (Amber) — The High Exhaust Temperature (HEST) indicator is displayed when the exhaust temperature reaches 300°C (572°F) and the regeneration process begins. When the regeneration process is completed, the engine should be allowed to run until the HEST indicator shuts off. During regeneration while the vehicle is moving, the HEST indicator will only illuminate when vehicle speed is less than 8 kph (5 mph).
  • Page 68 INSTRUMENTS AND CONTROLS 57 • Right-Hand Operation Indicator — Indicates that a right-hand drive mode has been enabled. • Maintenance Due Indicator — Indicates that a maintenance alert has been issued (maintenance is due). • Optional Tell-Tales • Aftertreatment DPF Regeneration Inhibit Icon — Illuminates when the inhibit switch is turned on.
  • Page 69 58 INSTRUMENTS AND CONTROLS • Malfunction Indicator lamp (MIL )— MIL indicates government Regulation On Board Diagnostics (OBD) faults. Lamp remains active after repair until system operation confirms repair. • Electronic Malfunction Indicator (Amber) — Illuminates when V-MAC® detects an electronic malfunction. Refer to the appropriate V-MAC® Operator’s Guide for details.
  • Page 70 • 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 shutdown option is enabled.
  • Page 71 60 INSTRUMENTS AND CONTROLS 9. 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.
  • Page 72 INSTRUMENTS AND CONTROLS 61 14. Hour Meter — Indicates hours of engine operation. Hours of operation should be used as a guide for certain engine or PTO maintenance operations. 15. CB Radio Auxiliary Hookup 16. DPF Smart Switch (If Equipped) — This is a three-position switch where the middle position is neutral.

  • Page 73: Dpf Inhibit Road Speed Limiting (Rsl)

    62 INSTRUMENTS AND CONTROLS DPF INHIBIT ROAD SPEED LIMITING (RSL) The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen) position by the driver. If the DPF Smart Switch remains in the locked position, the following vehicle speed limiting will occur: 1 Vehicle Moving.
  • Page 74 INSTRUMENTS AND CONTROLS 63 17. Inter-Axle Power Divider Lockout Switch (If Equipped) — See Inter-Axle Power Divider Lockout in the OPERATION section of this handbook on . C0029594 18. 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.
  • Page 75 64 INSTRUMENTS AND CONTROLS 19. Windshield Wiper/Washer Controls — Depress the ON/OFF button to turn the windshield wipers on or off. Pull the button up to make the wipers faster, push the button down to make the wipers slower. Depress the "WASH" button to activate the washer fluid.
  • Page 76 INSTRUMENTS AND CONTROLS 65 24. Parking Brake Valve — Pull to apply. Push to release. Applies tractor parking brakes and trailer brakes, if equipped. 25. Auxiliary Switch — As defined by the Body Builder. 26. Light Control Panel — See the LIGHT CONTROL PANEL section for more information.
  • Page 77 66 INSTRUMENTS AND CONTROLS 30. Heated Mirror Switch (If Equipped) — Activates the outside heated mirrors (for use in icy conditions). C0029598 31. Resume/Set Switch — This is a V-MAC® switch; for more information, refer to the applicable V-MAC® Operator’s Guide. C0029150 32.
  • Page 78 INSTRUMENTS AND CONTROLS 67 Accessory Power Outlet — See instructions under Accessory Power Outlets listed in the Instrument and Controls Section of this manual. 34. 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.

  • Page 79: Cab Climate Control

    68 INSTRUMENTS AND CONTROLS CAB CLIMATE CONTROL C0029599 1. Fan Control Switch 3. Temperature Control Lever 2. Mode Selection Lever 1. Fan Control Switch — Controls the amount of air delivered through the vents. Down is OFF and up is HIGH speed. The middle positions are LOW and MEDIUM speeds.

  • Page 80: Light Control Panel

    INSTRUMENTS AND CONTROLS 69 LIGHT CONTROL PANEL This panel controls the parking lights, interior panel lights, headlights and fog lights (if equipped). C0029600 1. Light Control Knob/Pull for Fog 3. Hook-Up Lamps or Perimeter Lighting (If Equipped) 2. Panel Dimmer Switch With the light control knob in the left position, all lights are off.

  • Page 81: Steering Column

    70 INSTRUMENTS AND CONTROLS STEERING COLUMN Combination Starter and Electrical Switch Turn Signal Lever Note: The turn signals are not self-cancelling and must be returned to the middle position manually. The turn signal lever is located on the steering column. It performs a number of functions, including activating the high and low beams and the hazard switch (see illustration on following page).

  • Page 82: Miscellaneous Controls

    INSTRUMENTS AND CONTROLS 71 MISCELLANEOUS CONTROLS Dome Light C0029602 Push the switch to the right to turn the dome light on. Push the switch to the left to turn the dome light off. Air Horn C0029603 The air horn(s), if equipped, is activated by pulling down on the cord that is located above the driver near the overhead console.

  • Page 83: Fresh Air Vent

    72 INSTRUMENTS AND CONTROLS Fresh Air Vent C0029604 An air vent, located in the driver side door, is provided to circulate outside air to the cab interior. Move the vent lever forward or rearward to open the vent. Move the lever to the center to close the vent. Accessory Power Outlets Additional 12-volt accessory power outlets are located next to the driver on the "E"...

  • Page 84: Pre-Trip Inspection And Daily Maintenance

    Whenever equipment requires adjustment, replacement, repair or lubrication, refer to the Service Manuals or contact an authorized Mack Truck dealer for the correct procedures, specifications and intervals. Take your time going through the pre-trip inspection. Remember that a careful pre-trip inspection saves time by eliminating unscheduled stops for correcting a faulty item.
  • Page 85 74 PRE-TRIP INSPECTION AND DAILY MAINTENANCE • Check under the vehicle for oil, fuel, coolant leaks or other signs of damage. • Check body surfaces for signs of breaks or damage. Preparation • Open drain cocks on air tanks to let the tanks drain. •...
  • Page 86 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 75 • Check slack adjuster and chamber pushrod travel for proper brake adjustment. Condition of Front Axle and Steering System, Left Side • No loose, worn, bent, damaged or missing parts. Engine Compartment, Left Side •...
  • Page 87 76 PRE-TRIP INSPECTION AND DAILY MAINTENANCE • Left and right front turn signal lights clean, operating and proper color. Grille • Check that charge air cooler and radiator or bugscreens are clean and undamaged. Step 3: Right Side of Cab Area Right Front Wheel •...
  • Page 88 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 77 Right Fuel Tank(s) • Securely mounted Diesel and Diesel Exhaust Fluid are not damaged or leaking. • Fuel lines secure and not leaking. Check that shut-off valves are open. • Tank(s) full of fuel. Cap on and secure. Condition of Visible Components •...
  • Page 89 78 PRE-TRIP INSPECTION AND DAILY MAINTENANCE • 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 for proper adjustment.
  • Page 90 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 79 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, missing clamps or lug nuts. •...
  • Page 91 80 PRE-TRIP INSPECTION AND DAILY MAINTENANCE • Fuel lines secure and not leaking. Check that shut-off valves are open. • Tank(s) full of fuel. Cap on and secure. Battery Area • Open the battery box. Battery box securely mounted to vehicle. •...
  • Page 92 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 81 Hook-Up Preparation • Check kingpin and mounting plate on trailer, free from wear, bends or damage. • Chock trailer wheels. Fifth Wheel or Trailer Hitch • No visible space between fifth wheel and trailer. •...
  • Page 93 82 PRE-TRIP INSPECTION AND DAILY MAINTENANCE • Carrier or rack not damaged. • Spare wheel securely mounted in rack. • Tire and wheel condition adequate for a spare: proper size, properly inflated. Lights and Reflectors • Trailer side clearance lights: clean, operating and proper color. •...
  • Page 94 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 83 • 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. •...
  • Page 95 84 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 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.
  • Page 96 PRE-TRIP INSPECTION AND DAILY MAINTENANCE 85 Frame and Body • Frame and crossmembers not bent, cracked, damaged or missing. • Proper placarding. • Body parts not damaged or missing. Before Leaving the Parking Area • Remove chocks from the wheels. •...

  • Page 97: 86 Operation

    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.
  • Page 98 • On chassis equipped with AIRTEK™ front axle air suspensions, retorque the U-bolts. • Check the U-bolt torque on the MACK air suspension at the end of the first 1600 km (1000 miles). After the First 5000 Kilometers (3000 Miles) or Before 6400 Kilometers (4000 Miles) or Before 3 to 4 Months •...

  • Page 99: Windshield Washer Reservoir

    88 OPERATION WINDSHIELD WASHER RESERVOIR As shown in the drawing below, the windshield washer reservoir is located on the driver-side back of the cab. C0029606...

  • Page 100: Cab Tilt Operation

    OPERATION 89 CAB TILT OPERATION DANGER Before attempting to tilt the cab, be certain to take the following steps: • Park on a level surface. • Apply the parking brake. • Place the gearshift lever in NEUTRAL position. • Shut off the engine. •...

  • Page 101: Tilting The Cab

    90 OPERATION Tilting the Cab Use the following instructions to tilt the cab: Note: Before raising the cab, the engine must be shut off and all loose items in the cab must be secured. 1. Take the cab tilt pump handle from its stored position. Note: The cab tilt pump handle is stored inside the cab, on the right side cab back wall, behind the folding seat.
  • Page 102 OPERATION 91 3. To raise to the service position, pump the cab up to the SERVICE HEIGHT position. C0029616 1. Safety Prop Note: In the service position, the cab must be secured with the safety prop (see illustration). 4. To secure the cab in the service position, loosen the thumbscrew and swing the safety prop down onto the safety prop stud (see arrow).

  • Page 103: Lowering The Cab

    92 OPERATION C0029617 1. Cab Full Tilt Position 6. To raise the cab to the full tilt position, pump the cab up past the balance point. Note that the cab will descend by itself, although the rate of descent may be controlled by manipulating the pump control lever from the RAISE to LOWER position.

  • Page 104: Bleeding The Cab Tilt System

    2. Tighten all connections (except two) at the tilt cylinder. 3. Tighten one connection at each latch cylinder. 4. Fill the pump reservoir to the top with MACK specified oil. CAUTION Do not refill the reservoir with the cab in the RAISE position.

  • Page 105: Doors

    94 OPERATION DOORS Opening the Cab Door The inside door handles are flush-mounted, with paddle-type design. To open the door, grasp the handle and pull out while exerting some force on the door. C0029618 Note: If the door is locked, slide the button to unlock the door before pulling the inside paddle handle.
  • Page 106 OPERATION 95 1. Open the right-side door. Note that the right-side door opens the same way as the left side, using a paddle-type handle. C0029619 2. With the door open at least halfway, lift up on the door bottom and fold the door in half (refer to the illustration).
  • Page 107 96 OPERATION C0029620 1. Pull the paddle handle door latch (see arrow) and use both hands to support the door while unlatching the ball and socket (which is holding up the lower half of the door). Refer to the illustration. 2.

  • Page 108: Folding The Door

    OPERATION 97 C0029621 3. Pull the door about six inches away from your body, and carefully lower the folded section to the whole-door position. Bi-Fold Doors The LEU model can be equipped with optional bi-fold doors on both sides of the chassis. Procedures for unfolding and folding the door are the same on both sides of the vehicle.
  • Page 109 98 OPERATION C0029622 2. Rotate the bi-fold latch handle upward to disengage the slot. Pull the handle rearward to unlatch the bi-fold door panels. C0029623 3. Fold the two door panels until they latch together. In this position, the cab door latch acts as a holding device to secure the bi-fold panels together.
  • Page 110 OPERATION 99 C0029624...

  • Page 111: Unfolding The Door

    100 OPERATION Unfolding the Door 1. Push the door latch lever located on the front of the cab to disengage the door panels from the cab. C0029625 2. Pull the outside door handle to separate the two door panels. C0029626 3.
  • Page 112 OPERATION 101 5. Reinstall the door limiting strap.

  • Page 113: Seat Belts

    Seat Belt Operation MACK vehicles manufactured on or after September 1, 1990 must have locking retractable seat belts. This type of belt is designed to lock (prevent belt travel out of the retractor) only during sudden stops or impacts.
  • Page 114 OPERATION 103 DANGER To prevent possible injury the belt must be positioned low over the pelvis, below the abdomen. If the belt is buckled too high, it will apply force to the abdomen, not the pelvic region, and could cause serious internal injuries during a sudden stop. DANGER Do NOT wear seat belt loosely.
  • Page 115 104 OPERATION Unfastening Seat Belt Push down on the button to release the belt. Seat Belt Maintenance • Keep belt clean and dry. • Clean with mild soap solution and lukewarm water. DANGER Do NOT bleach or dye belt, as this may cause severe loss of strength. Do NOT install belt in a truck with a weakened floor until the floor has been replaced or reinforced.

  • Page 116: Right-Side Restraint

    OPERATION 105 RIGHT-SIDE RESTRAINT C0029628 DANGER When the seat is in the standing (drive) position and the door is open, pull out the orange-colored retractable webbing and engage the end into the buckle in the instrument panel. This will serve as a door-opening restraint.

  • Page 117: Seat Adjustment

    106 OPERATION SEAT ADJUSTMENT Right-Side Folding Seat Note: This vehicle was designed as a left-hand drive cab with right-hand operating position. It is possible to operate this vehicle from either side, but the person on the right must be seated to ride and must stand to drive. C0029629 Stand facing the seat.

  • Page 118: Air Seat

    OPERATION 107 Air Seat C0029630 1. Lumbar Adjustment Knob 4. Weight and Height Adjustment Button 2. Seat Back Adjustment Lever 5. Seat Cushion Tilt Adjustment Knob 3. Optional Air Lumbar Adjustment 6. Fore/Aft Adjustment Lever Button (Upper and Lower) DANGER Do not make seat adjustments while the vehicle is in motion, as this could cause a loss of vehicle control, resulting in an accident which results in severe personal injury or death.
  • Page 119 108 OPERATION 1. Lean forward slightly to remove your weight from the seat back. 2. Pull the seat back angle adjustment lever [2] rearward to release. 3. Adjust the seat back to the desired position within range of adjustment, then release the handle to lock the seat back into place.

  • Page 120: Mirror Systems

    OPERATION 109 MIRROR SYSTEMS The mirror system for LEU model chassis are designed so that: • Appropriate mirror views are available from both operating positions. Moto Mirror System The mirrors of the Moto Mirror System can be adjusted at any time (from inside the cab) using the adjustment switches located on the center instrument panel (Panel E).
  • Page 121 110 OPERATION C0029632 1. Forward 3. RH Driving Position 2. Wipers Must Park at the "Inboard" Position C0029633 1. Forward 3. LH Driving Position 2. Wipers Must Park at the "Inboard" Position...
  • Page 122 OPERATION 111 C0029634 1. Forward 3. RH Driving Position 2. Wipers Must Park at the "Inboard" Position...

  • Page 123: Mack Engine Information

    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.

  • Page 124: Engine Model Designations

    The maximum allowable engine speed is listed on the warning label on the sun visor. DO NOT exceed 2,300 rpm. Engine Model Designations The MACK engine model designation system uses letters and numbers to provide a complete unit description. MP Engine ID Letters and Number...

  • Page 125: Cruise Control Operation

    114 OPERATION CRUISE CONTROL OPERATION Note: Effective August 2008, a change was made to the vehicle software which requires the vehicle operator to press and release the brake pedal after the engine has been started. If the brake pedal is not depressed after starting the engine, cruise control will not function.

  • Page 126: Disengaging Cruise Control

    OPERATION 115 Disengaging Cruise Control To turn off the cruise control system, move the Speed Control switch to the OFF position. Note: If the Speed Control switch is moved to the OFF position, the process of setting cruise control must be repeated in order to re-activate cruise control (unless the Initial Set Using Resume Switch feature is enabled).

  • Page 127: Mack Powerleash™ Engine Brake (If Equipped)

    PowerLeash™ camshaft. These engines are identified on the engine information sticker. If your vehicle is equipped with the MACK PowerLeash™ Engine Brake, it is important that you take the time to become familiar with your engine brake before putting it into operation.

  • Page 128: Engine Brake Switch

    OPERATION 117 Engine Brake Switch The Engine Brake switch is located on the dashboard. The Engine Brake switch is a three-position switch located on the instrument panel. C0029330 To operate the vehicle without the engine brake active, leave the dash-mounted switch in the OFF position. CAUTION The V-MAC®...

  • Page 129: Cruise Control With The Mack Powerleash™ Engine Brake

    Cruise Control with the MACK PowerLeash™ Engine Brake When the MACK PowerLeash™ Engine Brake is enabled at the same time your V-MAC® cruise control is in use, the engine brake automatically activates when necessary to slow the vehicle to the cruise set point speed. You can select one of two possible options: •...

  • Page 130: On The Road With The Mack Powerleash™ Engine Brake

    If you are not familiar with the use and operation of a heavy-duty diesel engine brake, it is essential that you read the following section carefully. It is very important that you take the time to gain experience with your MACK PowerLeash™ Engine Brake in good driving conditions, before using it in difficult or hazardous driving conditions, such as steep descents or slippery roads.

  • Page 131: Descending A Grade

    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.
  • Page 132 C0029333 1. Descent Speed without MACK Engine Brake Switch the MACK PowerLeash™ Engine Brake to the HIGH position, and now it is possible to descend the same grade in sixth gear to maintain a steady 56 kph (35 mph) at 2,000 engine rpm.

  • Page 133: On Slippery Road Surfaces

    On Slippery Road Surfaces As with many aspects of operating a heavy-duty vehicle, special care should be taken when using the MACK PowerLeash™ Engine Brake on slippery road surfaces. The potential for unpredictable loss of vehicle traction is a serious concern;...
  • Page 134 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.

  • Page 135: Brake Operation

    124 OPERATION BRAKE OPERATION Air Brake System This chassis features a dual braking system which has two complete air circuits: a primary circuit for rear brakes and a secondary circuit for front brakes. Each circuit receives air from separate reservoirs. Although there are two air circuits, they operate as one brake system through the dual-circuit treadle valve.

  • Page 136: Automatic Slack Adjusters

    OPERATION 125 When slowing for a stop, leave the clutch engaged for as long as possible to use the braking effect of the engine. When forward speed has dropped to a little above idling speed, push clutch pedal in and brake to a complete stop. Automatic Slack Adjusters Automatic slack adjusters are designed to automatically maintain proper brake chamber pushrod travel and compensate for brake lining wear during normal...

  • Page 137: Parking Brake Operation

    126 OPERATION Parking Brake Operation The parking brakes can be applied and released from the cab, using the hand-operated push/pull control valve with the yellow diamond knob. In the event of a significant air pressure loss in both the air brake systems, the spring brake air chambers will be automatically exhausted (applying the brakes).

  • Page 138: Anti-Lock Brake System (Abs)

    Advanced EC-60™ Electronic Control Unit. In most cases, vehicle repairs will not affect function of the MACK RSA system. However, the following repairs require recalibration of the SAS-60™ sensor after the repair has been made: •...
  • Page 139 128 OPERATION • Front end alignment • Disconnecting the steering column from the steering gear, or the steering linkage from the steering gear WARNING Failure to recalibrate the steering angle sensor after performing any of the repairs mentioned above, may affect proper function of the RSA system, resulting in a loss of vehicle control due to system intervention at inappropriate times.
  • Page 140 OPERATION 129 • Changes to steer axle and/or drive axle track width • Changing the front and/or rear brake drums to drums having a different flange thickness Tire Size Calibration The ECU requires a precise rolling circumference ratio between the front steer axle and the rear drive axles for optimum performance of the system.

  • Page 141: Automatic Traction Control (Atc) (If Equipped)

    130 OPERATION 3. Listen for signs of air exhausting from ABS modulator valves (which is an indication of an interference condition). 4. Correct all interference conditions before operating the vehicle. Automatic Traction Control (ATC) (If Equipped) Automatic Traction Control (ATC) provides improved traction on slippery surfaces by reducing wheel spin.

  • Page 142: Work Brake System

    OPERATION 131 Work Brake System The work brake system is designed to be used when frequent stops are made. This type of operation, typical in house-to-house refuse collection, consumes large volumes of air if the spring brake is applied at each stop. The work brake system uses significantly less air volume than the spring brake system, improving overall brake system durability.
  • Page 143 132 OPERATION To release the work brake and place the automatic transmission back into the previously selected forward gear: 1. Apply the foot brake. 2. Lift and rotate the work brake lever counterclockwise (toward the windshield). 3. Lower the lever into the locked (released) position. Note: Engine speed must be below 900 rpm.

  • Page 144: Good Driving Habits

    OPERATION 133 GOOD DRIVING HABITS Weight Ratings Do not overload the vehicle. The gross vehicle weight rating (GVWR) and gross axle weight ratings (GAWR’s) for a given model may vary due to the tires, wheels/rims, suspensions, axles and/or frame of a specific vehicle. For safety and durability reasons, do not exceed the GVWR and GAWR’s listed on your vehicle’s Safety Certification Label.

  • Page 145: Starting The Vehicle

    134 OPERATION STARTING THE VEHICLE General Information Before putting the key in the ignition switch, set the parking (spring) brake, disengage the clutch (if equipped) and put the transmission in NEUTRAL. CAUTION Do not engage the starting motor too soon after an incomplete start of the engine, or the starter may be damaged.

  • Page 146: Air Starters

    OPERATION 135 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...
  • Page 147 136 OPERATION Priming the MP Fuel System DANGER Before working on or inspecting a vehicle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. DANGER To avoid potential fire hazard, do not service any part of the fuel system while smoking or in the presence of flames, sparks or hot surfaces, or when working on...
  • Page 148 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.

  • Page 149: Engine Warm-Up

    138 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. Engine damage can occur if the engine is not warmed up to a minimum operating temperature of 77°C (170°F) before putting the vehicle into full operation.

  • Page 150: Shutting Down The Engine

    V-MAC IV Shutdown Option: Idle Cooldown This feature provides a means of cooling down the engine and turbocharger. If the idle cooldown option is enabled using VCADS Pro MACK Support Software and the system senses that the turbocharger may be hot, the engine will not shut down when the vehicle stops, the parking brake is set and the key switch is turned to the OFF position.
  • Page 151 140 OPERATION 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.

  • Page 152: Cold Weather Operation

    OPERATION 141 COLD WEATHER OPERATION DANGER Do NOT, under any circumstances, use starting fluid (ether) on engine whether or not equipped with an inlet manifold air heater element. An explosion can occur. Cold Weather Starting Tips • Save the batteries. Do not overtax the batteries by cranking the starter for more than 30 seconds without interruption.

  • Page 153: Engine Block Heaters

    142 OPERATION Engine Block Heaters An engine block heater works by heating the coolant surrounding the combustion chambers. Engine heaters are recommended to help combat the extreme demands of cold weather operating conditions. When the temperature drops, the engine heater can be plugged in overnight. The location of the engine heater power receptacle varies according to vehicle design.

  • Page 154: Moving The Vehicle - General Information

    OPERATION 143 MOVING THE VEHICLE — GENERAL INFORMATION Braking Avoid sudden stops. Constant sudden stops may negatively affect braking performance and driving parts. When slowing, leave the clutch (if equipped) engaged as long as possible to use the braking effect of the engine. CAUTION When using the braking effect of the engine, final gear selection is critical.
  • Page 155 144 OPERATION — Stop the vehicle. — Put the transmission in NEUTRAL. — Set the parking brake. — Go to the right side of the vehicle. — Flip the switch to the right.

  • Page 156: Transmission Shifting Instructions

    OPERATION 145 TRANSMISSION SHIFTING INSTRUCTIONS CAUTION Never coast with the transmission in neutral. Never coast with the clutch depressed. ALLISON TRANSMISSION SHIFTING INSTRUCTIONS For additional information, refer to your Allison transmission manual supplied with your vehicle. Allison 4500 RDS, WTEC III Controls and 4th Generation Controls Shifting Instructions with Allison Transmission Electronic Control WARNING Do NOT allow your vehicle to coast in NEUTRAL.
  • Page 157 146 OPERATION CAUTION The Allison 4500 RDS transmission will not operate in lockup mode when an active ABS fault exists. Prolonged operation of the transmission while an ABS code is active can overheat the transmission oil. Note: TranSynd™ and the most current specification DEXRON® fluids are recommended for all RDS transmission applications.
  • Page 158 OPERATION 147 Use this to back the vehicle. Completely stop the vehicle and let the engine return to idle before shifting from forward to reverse or from reverse to forward. The reverse warning signal sounds when this gear is selected. The digital display will display R when reverse is selected.

  • Page 159: Status Lights

    148 OPERATION C0029635 Status Lights Check Trans Light — Illumination of this indicator notifies the driver of a problem with the transmission system and automatically takes action to protect the driver, vehicle and transmission. For 4500 RDS transmissions, when the Electronic Control Unit (ECU) detects a problem condition, the ECU will restrict shifting, turn on the CHECK TRANS light on the instrument panel, and register a diagnostic code.

  • Page 160: Transmission Module Location

    OPERATION 149 Transmission Module Location The Electronic Control Unit (ECU) is located in the compartment below the left-side driver seat. Note: Shifting is restricted to second gear when the vehicle is being operated from the right-hand driving position. Note: For body builders, applicable connections have been reduced to one plug which is located in the compartment below the left-side driver’s seat.

  • Page 161: Axles

    All four-wheel-drive tandem carriers are available with the MACK inter-axle power divider third differential (with or without a power divider lockout). MACK rear axles are designed so the entire load is carried by the axle housing (through the wheel bearings mounted on the housing spindle). The rear axle shafts are either free-splined (both ends) or integral flange type.

  • Page 162: Engaging The Power Divider Lockout

    OPERATION 151 Inter-Axle Power Divider Lockout (If Equipped) The MACK power divider can be rendered inoperative, during short periods of poor traction, using a power divider lockout. When the power divider lockout is engaged, both axles are locked together (in positive through-drive) for maximum traction with no differential action between axles.
  • Page 163 152 OPERATION 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. LIFTABLE AXLES Liftable (tag and pusher) axles are used to distribute weight evenly across the chassis so maximum payload can be accommodated with various state weight regulations.
  • Page 164 OPERATION 153 Axle air pressure should be set to provide proper weight distribution across the chassis and to conform to local weight regulations. In general, a setting of 60 to 70 psi is adequate for most applications, but an accurate setting should be determined by weighing the axles and adjusting the air pressure accordingly.

  • Page 165: Extended Idling And Aftertreatment System Conditioning

    154 OPERATION Extended Idling and Aftertreatment System Conditioning Extended idling performed on this vehicle equipped with an exhaust aftertreatment system should be carried out at a low engine idle speed. There is no benefit to using a raised engine idle speed for extended idling. The only exception is for active PTO operation.

  • Page 166: Mack, Us10 Emissions Solution 155

    Mack, US10 Emissions Solution 155 DIESEL PARTICULATE FILTERS Your new MACK chassis is equipped with a 2010 emission compliant engine and an exhaust aftertreatment system which includes a Diesel Particulate Filter (DPF), which reduces soot and particulate emissions into the atmosphere.
  • Page 167 As well as two different mounting styles: 1. MACK Vertical Back-of-Cab DPF both conventional DPF or conventional DPF or TRU 2. Mack-Cap DPF, which is a space saying unit that is mounted inside the frame (conventional only) C0029353 A Diesel Particulate Filter (DPF) takes the place of the standard muffler. The DPF is used to meet EPA requirements to help reduce soot and particulate emissions into the atmosphere.
  • Page 168 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.

  • Page 169: Exhaust Aftertreatment System

    158 Mack, US10 Emissions Solution Exhaust Aftertreatment System LEU Standard System View W2031562...

  • Page 170: Safety Information

    SCR process. It’s a nontoxic, ultra-pure solution of urea and Safety Information Mack utilizes the use of a Diesel DANGER Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) to meet Exhaust gases and components can EPA2010 emissions.

  • Page 171: Exhaust Aftertreatment System Components And

    160 Mack, US10 Emissions Solution Exhaust Aftertreatment System Components Selective Catalytic Reduction (SCR) Selective Catalytic Reduction (SCR) is an aftertreatment systems, called diesel emissions-reduction technology with the particulate filters, to control emissions of ability to deliver near-zero emissions of another pollutant, soot (also known as nitrogen oxides (NOx), a smog-causing particulate matter or PM).
  • Page 172 -- for better combustion, while meeting the EPA NOx emissions requirement. By using DEF, we avoid the disadvantages of increasing EGR to massive levels. This results in better fuel economy from your Mack engine. W2055490 Vertical SCR, side inlet...

  • Page 173: Diesel Exhaust Fluid (Def)

    162 Mack, US10 Emissions Solution W3036787 Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid (DEF) is a reactant urea. Use of fluids other than API certified that’s key to the SCR process. It’s a Diesel Exhaust Fluid will compromise nontoxic, ultra-pure solution of urea and aftertreatment system performance, ultra-pure water.
  • Page 174 Mack, US10 Emissions Solution 163 Diesel Exhaust Fluid (DEF) Handling When handling DEF solution, it is CAUTION important to prevent contact with electrical connections. There is a risk that the DEF will cause oxidation that cannot When detaching hoses and components, be removed.
  • Page 175 164 Mack, US10 Emissions Solution visit the website www.Mackscr.com or please contact Mack One-Call at 1–800–866–1177.

  • Page 176: Aftertreatment Diesel Particulate Filter (Dpf)

    CAUTION operation, this indicates a problem with the exhaust aftertreatment system. Take the vehicle to an authorized Mack Truck Use of diesel fuel other than ULSD and dealer immediately. engine oils other than EO-O Premium...

  • Page 177: Aftertreatment Control Module (Acm)

    166 Mack, US10 Emissions Solution Aftertreatment Control Module (ACM) 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 •...
  • Page 178 Mack, US10 Emissions Solution 167 Aftertreatment DPF Regeneration DPF Smart Switch– This is a three-position switch where the middle position is neutral. C0029148 DPF Smart Switch 1. Upper Position – Regeneration 3. Down Position – Inhibit Position (if Position equipped) 2.
  • Page 179 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.
  • Page 180 Mack, US10 Emissions Solution 169 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.
  • Page 181 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.
  • Page 182 Mack, US10 Emissions Solution 171 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 for additional Aftertreatment DPF System Information sun visor label information.

  • Page 183: Driver Warnings And On Board Diagnostics (Obd)

    172 Mack, US10 Emissions Solution Driver Warnings and On Board Diagnostics (OBD) On Board Diagnostics (OBD) Beginning with your US 2010 compliant the vehicle operator to any detected need Vehicle, On Board Diagnostics (OBD) is for an emission related repair. When the introduced.

  • Page 184: Instrument Cluster

    Mack, US10 Emissions Solution 173 Instrument Cluster The aftertreatment icons are located in the instrument cluster per the following images. LEU Instrument Cluster W3031622 A Left Side Indicator Set B Right Side Indicator Set 1. Malfunction Indicator 2. CHECK Lamp 3.

  • Page 185: Malfunction Indicator Lamp (Mil)

    174 Mack, US10 Emissions Solution Instrument Cluster Icons Aftertreatment icons are displayed on temperature during a moving regeneration. the instrument cluster. There are 3 When the HEST icon is illuminated, do aftertreatment icons: not park or operate the vehicle near people, •...

  • Page 186: Aftertreatment Def Tank Level - Driver Warning & Inducement

    Mack, US10 Emissions Solution 175 Aftertreatment DEF Tank Level - Driver Warning & Inducement Aftertreatment DEF tanks are sized to The vehicle instrument cluster has a have no less than 2 times the diesel fuel Aftertreatment DEF Tank Level Gage...

  • Page 187: Aftertreatment Def Quality - Driver Warning & Inducement

    176 Mack, US10 Emissions Solution Aftertreatment DEF Quality - Driver Warning & Inducement Triggers Aftertreatment Amber Warning Inducement DEF Tank Low Lamp Level Indicator None None None Good DEF Quality None None Poor DEF Quality DTC Initial Detected W3031623 Poor DEF Quality...

  • Page 188: Misfilling Diesel Or Aftertreatment Def Tanks

    Mack, US10 Emissions Solution 177 Exit conditions for DEF Quality "5 mph road speed limit" Inducement: First Restart: Return to 25% torque reduction until proper DEF quality evaluation. If poor DEF quality is detected during the next monitoring cycle then and 5 mph resumed after vehicle stationary for 20 minutes.

  • Page 189: Scr Tampering - Driver Warning & Inducement

    178 Mack, US10 Emissions Solution SCR Tampering - Driver Warning & Inducement 1. Disconnected Aftertreatment DEF tank 4. Disconnected Aftertreatment DEF level sensor pump 2. Blocked Aftertreatment DEF line or 5. Disconnected SCR wiring harness dosing unit 3. Disconnected Aftertreatment DEF 6.

  • Page 190: Warranty And Maintenance

    Mack, US10 Emissions Solution 179 Warranty and Maintenance Exhaust Aftertreatment System Maintenance The vehicle must be taken to an authorized Mack Truck dealer to remove the ash from the Aftertreatment Diesel Particulate Filter and clean the Aftertreatment Doser. Engine Maintenance Intervals...

  • Page 191: 180 Maintenance And Lubrication

    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.

  • Page 192: Turbocharger

    MAINTENANCE AND LUBRICATION 181 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.

  • Page 193: Cleaning Your Vehicle

    182 MAINTENANCE AND LUBRICATION CLEANING YOUR VEHICLE The best protection against environmental influences that can hurt your vehicle’s finish is frequent washing and waxing. How often this is required depends on how much the vehicle is used, where it is parked and weather conditions.
  • Page 194 Use of these types of products will damage the paint finish and void the vehicle warranty. Mack Trucks, Inc. has approved EL-ReadyMix Truck Wash & Wax for removing concrete from the vehicle surfaces.

  • Page 195: Cab And Hood

    The 3M company and Mequiar’s® have a complete line of automotive cleaning products available that are approved for use on MACK vehicles. • Rinse the sponge or brush often to keep it clean.

  • Page 196: Waxing

    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.

  • Page 197: Towing

    186 MAINTENANCE AND LUBRICATION TOWING Tow pins, hooks, eyes, etc., are located in or behind the front bumper. These devices meet the recommendations for towing set forth by the Technology and Maintenance Council (TMC) of the American Trucking Association and can be used for towing a disabled vehicle from the immediate location.
  • Page 198 MAINTENANCE AND LUBRICATION 187 C0029644...

  • Page 199: Engine Oil Level Check

    188 MAINTENANCE AND LUBRICATION ENGINE OIL LEVEL CHECK As the operator of this vehicle, it is important for you to perform the daily inspections necessary to keep your truck in good shape. Maintaining the proper oil level in your engine crankcase cannot be overemphasized. Before checking the oil, remember these important points: •...

  • Page 200: Power Steering Reservoir

    MAINTENANCE AND LUBRICATION 189 Power Steering Reservoir The Power Steering system uses only DEXRON® type automatic transmission fluid. C0029645 Power Steering Reservoir 1. Power Steering Reservoir For additional information about power steering, refer to the Maintenance and Lubrication Manual (21394653).

  • Page 201: Fuel Tank

    Your vehicle may be equipped with an isolated fuel tank. If so equipped, the following label will be affixed to the fuel tank decal. C0029424 Fuel Tank Cap Use MACK approved non-vented cap only or tank damage and/or poor engine performance may result. DO NOT fill to more than 95% of liquid capacity.

  • Page 202: Fueling

    MAINTENANCE AND LUBRICATION 191 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.

  • Page 203: Biodiesel

    As a result, Mack does not warrant the engine will conform to applicable Federal or California emissions limits when operated on, or having operated on, biodiesel or other alternative fuels that are not substantially similar to specified test fuels used for certification.
  • Page 204 MAINTENANCE AND LUBRICATION 193 blends conform to ASTM D975, and B6 to B20 blends conform to ASTM D7467. Failures of certain emissions aftertreatment components, specifically SCR, DPF and NOx sensors will not be warranted if the failure can be attributed to operation on biodiesel blends from 6 to 20% (B6 to B20) even if the biofuel used in the blend B6 to B20 conforms to ASTM D7467 or any related standard.

  • Page 205: Cooling System

    NOT depress. After the pressure has completely dissipated, press the cap downward and continue turning to remove. Your MACK model chassis has a pressurized surge tank located on the left-hand side of the chassis, mounted on the air cleaner assembly support bracket.

  • Page 206: Draining The Cooling System

    MAINTENANCE AND LUBRICATION 195 W2056638 Draining the Cooling System Whenever repairs are to be made which would require disconnection of coolant hoses, etc., the cooling system should be drained. Carefully remove the filler cap and remove all pipe plugs. Refilling the Cooling System Close all drain cocks and fill with the proper coolant mixture.

  • Page 207: Protecting The Cooling System

    Ethylene glycol or propylene glycol-based antifreezes are both approved for all MACK engines. All ethylene glycol and propylene glycol coolants must be low-silicate antifreezes which meet ASTM4985 test (GM6038M SPEC) criteria. These antifreezes are sometimes referred to as heavy-duty diesel coolants.

  • Page 208: Cooling System Maintenance

    Do NOT use coolant solutions which contain anti-leak additives in trucks equipped with coolant filters or conditioners. CAUTION Do NOT use soluble oil-type coolants in any MACK cooling system. Cooling System Maintenance The cooling system must be maintained by performing regularly scheduled maintenance as outlined in the Maintenance and Lubrication Manual (21394653).

  • Page 209: Accessory Drive Belt Routing

    198 MAINTENANCE AND LUBRICATION Accessory Drive Belt Routing The following diagram shows the accessory drive belt and main belt routing with and without air conditioning. This diagram is located in a clear area on the outside of the left frame between the radiator and center line of the front axle. C0029647 Accessory and Main Drive Belt Routing 1.

  • Page 210: Headlights

    MAINTENANCE AND LUBRICATION 199 HEADLIGHTS Bulb Replacement Note: This vehicle uses a sealed beam type headlamp bulb which is not replaceable without special tools. This vehicle should be taken to a qualified Mack Trucks dealer for replacement. WHEELS Wheel Inspection Look at the wheels and cap nuts.

  • Page 211: Tires

    200 MAINTENANCE AND LUBRICATION 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.
  • Page 212 MAINTENANCE AND LUBRICATION 201 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.
  • Page 213 202 MAINTENANCE AND LUBRICATION CAUTION For important tire information (i.e., high speed limits, inflation pressures, etc.), consult the product information available through the specific tire manufacturer. Oil Contamination of Tires Lubricating oils, fuel oil, gasoline and other petroleum derivatives, if allowed to contact tires, will soften the rubber and destroy the tire.

  • Page 214: Battery

    MAINTENANCE AND LUBRICATION 203 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.
  • Page 215 204 MAINTENANCE AND LUBRICATION 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.

  • Page 216: Electrical

    MAINTENANCE AND LUBRICATION 205 ELECTRICAL Circuit Breaker and Relay Panels The electrical equipment cover for this vehicle is located under the dash on the left-hand side of the cab. The label for this panel may be located under the driver left side operating position, behind the access panel. You need to remove the panel in order to view this label.
  • Page 217 206 MAINTENANCE AND LUBRICATION C0029649...
  • Page 218 MAINTENANCE AND LUBRICATION 207 C0029650 C0029651...
  • Page 219 208 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.

  • Page 220: Electrical Grease

    MAINTENANCE AND LUBRICATION 209 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.

  • Page 221: Circuit Protection Charts

    210 MAINTENANCE AND LUBRICATION Circuit Protection Charts Cab Circuit Protection (V-MAC IV) CB2 — 15 CB3 – 15 CB4 – 20A F5 – 10A Headlamps Hi Park & Tail Lps. Turn Signals Tractor Beam Emergency Stop Flasher Lps. F6 – 10A F7 –...
  • Page 222 MAINTENANCE AND LUBRICATION 211 Cab Circuit Protection (V-MAC IV) F39 — 30A F40 – 25A F41 – 15A F42 – 10A Body Ignition Engine Acc. Back-Up Lamp Trailer ABS Power Stud F43 — 15A F44 – 20A F45 – 30A F46 –...

  • Page 223: Metric Conversions

    212 METRIC CONVERSIONS METRIC CONVERSIONS Note: Use all tools on the fasteners they were made to be used on. Use metric tools on Sl metric units only. Never try to use metric tools on U.S. standard fasteners or U.S. standard tools on Sl metric units. CAUTION Potential external/internal thread mismatch condition(s) may occur with certain metric thread-inch thread fastener combinations, and with fastener combinations...
  • Page 224 METRIC CONVERSIONS 213 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...

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