Mack Granite GU Series Operator's Handbook Manual
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Mack Granite GU Series Operator's Handbook Manual

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Mack
®
Granite
TM
(GU Series)
21394647
© Mack Trucks, Inc. 2010
Printed in U.S.A.
Series
21394647
April 2010
Mack
®
Granite
TM
Series
(GU Series)

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  • Page 1 Mack ® Granite Series Mack ® Granite Series (GU Series) (GU Series) 21394647 21394647 © 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....16 Emissions Control System Warranty ...............18 SERVICE LITERATURE ....................22 – MACK Class 8 –Components Service Manual ............22 – Class 8 – Custom Collated Service Manual............22 – Class 8 – Custom Collated Service Manual on CD ..........22 CUSTOMER SERVICE ....................23...
  • Page 5 Deck Plate Access....................50 SAFETY TIPS FOR COLD WEATHER OPERATION ..........52 Driver Visibility .......................52 Cab Door Seals and Key Locks ................53 Outside Mirror Heater....................53 Air Horn Snow Shield....................54 Emergency Reflector Kit..................54 Fire Extinguisher (Optional) ..................54 INSTRUMENTS AND CONTROLS ................55 CAB INTERIOR......................55 INSTRUMENT PANEL ....................56 Tell-Tales........................56 Panel Arrangement....................57...
  • Page 6 MACK POWERLEASH™ ENGINE BRAKE (IF EQUIPPED)......151 Engine Brake Switch....................151 How the Engine Brake is Activated...............152 Cruise Control with the MACK PowerLeash™ Engine Brake ......153 ON THE ROAD WITH THE MACK POWERLEASH™ ENGINE BRAKE ..154 Over Flat Terrain....................154 Descending a Grade ....................155 On Slippery Road Surfaces..................157 BRAKE OPERATION....................159...
  • Page 7 MACK TM308M Shifting Instructions ..............197 MACK TM309 Shifting Instructions..............200 MACK TM309M Shifting Instructions ..............202 MACK T309, T309L and T309LR Shifting Instructions ........204 MACK T310 Shifting Instructions ................208 MACK T310M, T310ME and T310MLR Shifting Instructions ......210 MACK T313-T313L-T313LR Shifting Instructions ..........214 MACK T31321, T313L21 and T313LR21 Shifting Instructions ......218...
  • Page 8 Chassis Equipped with Snowplow Hood Option...........275 Power Steering Reservoir ..................276 FUEL TANK......................277 Fuel Tank Cap ......................277 FUELING ........................278 BioDiesel........................279 B5 Approval For Mack US10 Certified Products ..........280 COOLING SYSTEM....................281 Coolant Level Check....................281 Draining the Cooling System.................282 Refilling the Cooling System .................282...
  • Page 9 Protecting the Cooling System ................282 Cooling System Maintenance ................284 Accessory Drive Belt Routing ................284 HEADLIGHTS ......................286 Bulb Replacement....................286 WHEELS ........................287 Wheel Inspection ....................287 Tires ........................288 BATTERY........................291 Jump-Starting Engine.....................291 ELECTRICAL ......................293 Circuit Breaker and Relay Panels ................293 Electrical Grease ....................296 Circuit Protection Charts..................296 Electrical Accessory Connection Points ..............299 METRIC CONVERSIONS..................304 METRIC CONVERSIONS ..................304...
  • 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

    Note: Basic maintenance and lubrication procedures are found in this manual beginning with “MAINTENANCE INTRODUCTION”, page 266. For further information, refer to the Maintenance and Lubrication Manual . Other important information can be found in the Emission Control Systems for MACK Diesel Engine Manual.

  • 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

    Vehicles equipped with a Clean Idle engine are identified by a label which is affixed to the left front corner of the hood on conventional models (GU). W2056289 Clean Idle Engine Label Transmission Identification The MACK T300 Series transmission serial number is located on the rear left side of the main case.
  • Page 19 C0029891 All Eaton® Fuller® transmission identification plates are located on the front left side of the main case. C0028949 The MACK carrier assembly serial number is located on the front right side of the housing.
  • Page 20 INTRODUCTION 9 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.

  • Page 21: Warranty Information

    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 WARRANTY INFORMATION This chassis is equipped with a US’10 emission compliant engine and an exhaust aftertreatment system (Diesel Particulate Filter).

  • Page 22: Air Brake System

    INTRODUCTION 11 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 23 Control Systems of such engine and/or provided that such part(s) were returned to vehicle found to be defective upon Mack Trucks, Inc. or its nearest authorized examination by Mack Trucks, Inc. and Dealer within a reasonable period of time. Qualifications and Limitations: •...

  • Page 24: Emissions Control System Warranty

    INTRODUCTION 13 Emissions Control System Warranty The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal code of emission regulations. • 1 Turbocharger Assembly Aftertreatment Fuel Pressure Sensor • • Discharge Recirculation Valve VGT Actuator (DRV) (Heat Mode) 2 Charge Air Cooler...
  • Page 25 14 INTRODUCTION • • Aftertreatment DPF Outlet Aftertreatment DEF Return Temperature Sensor Valve • • Aftertreatment DPF Spark Assist Aftertreatment DEF Dosing Valve • Flame Temperature Sensor Aftertreatment DEF Tank • • Aftertreatment DPF Differential Aftertreatment DEF Tank Pressure Sensor Heater/Sender •...

  • Page 26: 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 27: 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 28 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 29: Emissions Control System Warranty

    18 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 30 INTRODUCTION 19 • • 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 31 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 32 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 33: 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 34: 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 35: Addresses

    24 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 36: Additional Assistance

    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 37: Reporting Safety Defects

    Contact Mack Trucks inc. de Mexico by calling 011-52-55-50-81-68-50 or by writing to: Mack Trucks Inc. de Mexico, S.A. de C.V., Prol. Paseo de la Reforma 600, 1er. Piso — 121, Col. Santa Fe Pena Blanca, C.P. 01210,...

  • Page 38: Event Data Recording Devices

    (trigger) an "event." Optional equipment available for your MACK vehicle, such as the Eaton® VORAD® Collision Warning System, may also provide event data recording features. If you have a question about your EDR, please contact your MACK dealer or regional service office.

  • Page 39: 28 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 40 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 41: 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 42 SAFETY INFORMATION 31 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 43: Advisory Labels

    The labels shown are applicable to the Mack® Granite™ GU model chassis at the time of publication and are representative of what can be typically found on a Mack® Granite™. (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.

  • Page 44: Advisory Label Locations (On Vehicle)

    SAFETY INFORMATION 33 Advisory Label Locations (On Vehicle) Labels Found on Chassis C0029831...
  • Page 45 34 SAFETY INFORMATION C0028958...
  • Page 46 SAFETY INFORMATION 35 C0028959...
  • Page 47 36 SAFETY INFORMATION C0029013 2. Hood Prop 1. Right Side Frame Rail...
  • Page 48 SAFETY INFORMATION 37 C0029014...
  • Page 49 38 SAFETY INFORMATION Labels Found on Driver-Side Sun Visor C0029832...
  • Page 50 SAFETY INFORMATION 39 C0029016...
  • Page 51 40 SAFETY INFORMATION Labels Found on Instrument Panel C0029017 Labels Found on Windshield C0029018 Note: Label to be removed upon delivery to the end user. Refer to “BRAKE OPERATION”, page 159 in the OPERATION section for additional information.
  • Page 52 SAFETY INFORMATION 41 R-134a Refrigerant Label The servicing caution label 4MR3283M is located under the hood attached to the receiver dryer bracket. C0029019 Eaton Controlled Traction Differential Label C0029020 Labels Found on Fuel Tank C0029021...
  • Page 53 42 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...

  • Page 54: Truck-Tractor Conspicuity

    SAFETY INFORMATION 43 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.

  • Page 55: Cab Entry/Exit

    44 SAFETY INFORMATION CAB ENTRY/EXIT Three-Limb Contact WARNING When entering or exiting a cab, the driver and/or passenger must have at least three limbs in contact with the vehicle or ground at all times. This means that a minimum of two hands and one foot, or one hand and two feet must be in FIRM contact with the vehicle or ground.
  • Page 56 SAFETY INFORMATION 45 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. •...

  • Page 57: 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 both hands or grab the outside handhold with one hand and grab the steering wheel or inside handhold (if equipped) with the other hand.
  • Page 58 SAFETY INFORMATION 47 C0029833...

  • Page 59: Passenger Side

    48 SAFETY INFORMATION Passenger Side The following cab entry and exit procedures, along with the safety guidelines outlined in the Three-Limb Contact section, should be used with this MACK vehicle. Entry These entry procedures are illustrated on the following page: 1 Facing the cab with both feet firmly on the ground, grab the outside handhold with both hands.
  • Page 60 SAFETY INFORMATION 49 C0029834...

  • Page 61: Deck Plate Access

    50 SAFETY INFORMATION Deck Plate Access There may be a time when you will need to climb up behind the cab. If your vehicle is equipped with a deck access package, steps and a handhold are provided so you can get to this area safely. Review the rules in the Three-Limb Contact section before climbing behind the cab.
  • Page 62 SAFETY INFORMATION 51 C0029835...

  • Page 63: Safety Tips For Cold Weather Operation

    52 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 64: Cab Door Seals And Key Locks

    SAFETY INFORMATION 53 • 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 65: Air Horn Snow Shield

    54 SAFETY INFORMATION Air Horn Snow Shield Installation of an air horn snow shield is recommended to prevent snow from clogging the air horn bell (maintaining maximum sound output). C0029133 Emergency Reflector Kit Your chassis may be equipped with an emergency reflector kit. Your kit includes red reflector triangles and can be stored in the following location: •...

  • Page 66: Instruments And Controls 55

    INSTRUMENTS AND CONTROLS 55 CAB INTERIOR C0029134 1. Instrument Panels 5. Hazard Switch 2. Cab Climate Control Panel 6. Turn Signal, Flash, HI/LO Beam, Courtesy Flash and Flash to Pass 3. Foot Pedals 4. Tilt Control Pedal...

  • Page 67: Instrument Panel

    56 INSTRUMENTS AND CONTROLS INSTRUMENT PANEL Tell-Tales A tell-tale is a display that indicates the actuation of a device, a correct or defective condition, or a failure to function. The operator should become familiar with these symbols in order to recognize and react (if necessary) to the indicated condition.

  • Page 68: Panel Arrangement

    INSTRUMENTS AND CONTROLS 57 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 69: Instrument Panel Gauge Layout

    58 INSTRUMENTS AND CONTROLS INSTRUMENT PANEL GAUGE LAYOUT The instrument panel features a wrap-around dash with electronically controlled "race type" gauges, meaning their needles point up when the truck is running properly. C0029135...
  • Page 70 INSTRUMENTS AND CONTROLS 59 W3056185 1. Manifold Boost Pressure 10. Air Suspension Pressure 2. Transmission Oil Temperature 11. Engine Oil Temperature 3. Exhaust Pyrometer 12. Air Application Pressure 4. Engine Coolant Temperature 13. Fuel Level 5. Engine Oil Pressure 14. Right Hand Tell-Tale 6.

  • Page 71: Panel A

    60 INSTRUMENTS AND CONTROLS Panel A C0029136 1. Manifold Pressure Gauge (If 4. Exhaust Pyrometer (If Equipped) Equipped) 2. Engine Oil Pressure Gauge 5. Transmission Oil Temperature Gauge (If Equipped) 3. Engine Coolant Temperature...

  • Page 72: Panel B

    INSTRUMENTS AND CONTROLS 61 Panel B W3056238...
  • Page 73 62 INSTRUMENTS AND CONTROLS 6. Aftertreatment DEF Level Gauge 21. Engine Over Speed Indicator (Red) 7. Integrated Temp-A-Start Indicator 22. Trailer Anti-Lock Brake System (Amber) (If Equipped). (ABS) Indicator (Amber) 8. Pre-Heat Start Indicator (Amber) 23. Cruise Control On Indicator (If Equipped) (Green) 9.

  • Page 74: Panel C

    INSTRUMENTS AND CONTROLS 63 Panel C C0029138 36. Air Application or Air Suspension 39. Air Suspension Pressure Gauge (If Equipped) 37. Hand-Control Brake Lever 40. Secondary Air Pressure Gauge 38. Engine Oil Temperature Gauge 41. Primary Air Pressure Gauge...

  • Page 75: Panel D

    64 INSTRUMENTS AND CONTROLS Panel D C0029139 42. Wiper Speed/Delay/Wash Master 58. Optional Switch* Switch 43. DPF Smart Switch (If Equipped) 59. Parking Brake Valve 44. Optional Switch* 60. Optional Switch* 45. Optional Switch* 61. Trailer Air Supply Valve 46. Optional Switch* 62.
  • Page 76 2. Engine 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).
  • Page 77 5. Transmission Oil Temperature Gauge (If Equipped) – Indicates transmission oil temperature. 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 with oil above this temperature will cause rapid deterioration of the oil’s lubricating properties and is NOT recommended.
  • Page 78 Brake Fault Threshold with Engine Brake" function. Refer to V-MAC® IV Customer Data Programming. Note: Consult the appropriate vendor engine manual if your vehicle is not equipped with a MACK engine. 11. Check Lamps 12. High Beam Indicator (Blue) – Indicates that high beams are on.
  • Page 79 68 INSTRUMENTS AND CONTROLS 15. Engine Shutdown Indicator (Red) – Indicates the occurrence of a condition which requires that the engine be shut down (i.e., low water level, low oil pressure or high water temperature). If the engine shutdown feature is enabled, the engine will be forced to idle.
  • Page 80 INSTRUMENTS AND CONTROLS 69 19. Basic Display or Co-Pilot® (If Equipped) BASIC DISPLAY The Basic Display is an in-dash computer that allows the vehicle operator to monitor a minimum amount of information supplied by the V-MAC IV electronic control system. The operator presses a push button located directly below the driver information display to retrieve information.
  • Page 81 70 INSTRUMENTS AND CONTROLS C0029141...
  • Page 82 INSTRUMENTS AND CONTROLS 71 Diagnostics W3036575 W3036576 W3036583...
  • Page 83 72 INSTRUMENTS AND CONTROLS Diagnostics (cont’d.) W3036584 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.
  • Page 84 INSTRUMENTS AND CONTROLS 73 C0029144...
  • Page 85 74 INSTRUMENTS AND CONTROLS • Manually through the GuardDog™ Status screen C0029145 For more information on GuardDog™, Co-Pilot® display and Basic Display, please refer to the V-MAC® IV Operator’s Guide. 20. Water in Fuel Indicator (Amber) (If Equipped) – Illuminates when water accumulates in the primary fuel filter sediment bowl.
  • Page 86 Equipped) – Indicate rear axle oil temperature. CAUTION The maximum safe oil temperature for MACK rear axles is 121°C (250°F). Continued with oil above this temperature will cause rapid deterioration of the oil’s lubricating properties and is NOT recommended. Consult the vendor manual for...
  • Page 87 76 INSTRUMENTS AND CONTROLS 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 517 kPa (75 psi) ±34 (±...
  • Page 88 INSTRUMENTS AND CONTROLS 77 43. DPF Smart Switch (If Equipped) – This is a three-position switch where the middle position is neutral. C0029148 DPF Smart Switch 1. Upper Position – Regeneration 3. Down Position – Inhibit Position Position 2. Middle Position – Neutral Position 44.
  • Page 89 Once the IPOD is connected, it will display a MACK logo on the IPOD screen and will let you know that the IPOD can now be controlled by the radio or steering wheel features (if equipped). At this point, the IPOD can be stored out of sight.
  • Page 90 INSTRUMENTS AND CONTROLS 79 73. Resume/Set Switch – This is a V-MAC® switch; refer to the V-MAC® IV Operator’s Guide for more information. C0029150 74. Speed Control Switch – This is a V-MAC® switch; refer to the V-MAC® IV Operator’s Guide (TS898) for more information. C0029211...

  • Page 91: Function Of Optional Switches

    80 INSTRUMENTS AND CONTROLS Function of Optional Switches C0029212 Optional Switches 1. Accessory Battery Power Switch 9. Fan Control Manual Override Switch 2. Accessory Ignition Power Switch 10. 5th Wheel Slide Switch 3. Air Suspension Control Switch 11. Inside/Outside Air Switch 4.
  • Page 92 INSTRUMENTS AND CONTROLS 81 C0029213 Optional Switches 1. Push Axle Up/Down Switch 7. Spin Light Switch 2. Push Axle Up/Down Switches 8. Strobe Switch 3. QUAL COMM Panic Button 9. Telma Retarder Lamp 4. Right-Hand Only Door Lock Switch 10. Vent Fan Switch 5.
  • Page 93 82 INSTRUMENTS AND CONTROLS The following optional switches, listed in alphabetical order, may appear on Panel D, shown on . • Accessory Switch (Battery Power) – This switch may be used to power optional accessory equipment that requires battery voltage, with the key switch turned OFF.
  • Page 94 C0029214 • Daytime Running Lights (DRL) Override Switch – Daytime Running Lights (DRL) come standard on all MACK vehicles and can be optioned with or without an override switch. When the DRL override switch has been specified, different conditions can be selected that cause the DRL to automatically activate, DRL can be automatically turned on when the parking brake is released, the engine is running or both.
  • Page 95 84 INSTRUMENTS AND CONTROLS 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.
  • Page 96 INSTRUMENTS AND CONTROLS 85 • Power Divider Lockout Switch – See "Inter-Axle Power Divider Lockout (If Equipped)" in the section of this manual. • Power Take-Off Control Switch — Press the top in to turn the PTO on. Push the bottom in to turn it off. •...
  • Page 97 86 INSTRUMENTS AND CONTROLS • Snow Plow Lamps Switch — Press the top of the switch to turn on the snow plow lamps if equipped. • Spin Light Switch — Press the top of the switch to activate the rotating beacon light.

  • Page 98: Cab Climate Control

    INSTRUMENTS AND CONTROLS 87 CAB CLIMATE CONTROL C0029218 1. Blower Control Knob 4. Fresh/Recirculation Button 2. Temperature Control Knob 5. A/C ON/OFF Button 3. Mode Knob 1. Blower Control Knob — This knob controls fan speed from OFF to 4 (highest speed).
  • Page 99 88 INSTRUMENTS AND CONTROLS 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).

  • Page 100: Sleeper Climate Control

    INSTRUMENTS AND CONTROLS 89 SLEEPER CLIMATE CONTROL C0029220 1. Fan Control Knob 3. Temperature Control Knob 2. Mode Selection Knob 1. Fan Control Knob — This is a three position knob to control the amount of air delivered through the sleeper box air vents. 2.

  • Page 101: Light Control Panel

    90 INSTRUMENTS AND CONTROLS LIGHT CONTROL PANEL The light control panel is located on the driver side of the dash. This panel controls the parking lights, interior panel lights, headlights and fog lights (if equipped). C0029221 Light Control Panel 3. Hook-Up Lamps or Perimeter 1.

  • Page 102: Lower Console Panel

    INSTRUMENTS AND CONTROLS 91 LOWER CONSOLE PANEL The lower console panel is located under the Cab Climate Control area of the middle dash. C0029222 1. Cigar Lighter 3. Accessory Power Outlet 2. Ashtray 4. Cup Holder...

  • Page 103: Steering Column

    92 INSTRUMENTS AND CONTROLS STEERING COLUMN Combination Starter and Electrical Switch The lower console panel is located under the Cab Climate Control area of the middle dash. C0029223 This switch starts the engine (turn the switch clockwise) and activates the accessory relay (turn the switch counterclockwise).

  • Page 104: Turn Signal Lever

    INSTRUMENTS AND CONTROLS 93 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, signal switch and the hazard switch.

  • Page 105: Stalk Switch (If Equipped, Co-Pilot® Only)

    94 INSTRUMENTS AND CONTROLS 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.

  • Page 106: Floor Pedals

    INSTRUMENTS AND CONTROLS 95 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.

  • Page 107: Miscellaneous Controls

    96 INSTRUMENTS AND CONTROLS MISCELLANEOUS CONTROLS Dome Light C0029228 Dome Light C0029229 Driver Side Switch C0029230 Passenger Side Switch With the switch in the bottom position on the driver side and on the passenger side, the dome light will come on when the cab door is opened and go off when it is closed.

  • Page 108: Interior Cab Lights (Sleeper Cab)

    INSTRUMENTS AND CONTROLS 97 Interior Cab Lights (Sleeper Cab) Various interior cab lights are activated using the rocker switches located in the headliner. C0029231 Driver Side 1. Map Light Switch Activates the 3. Sleeper Light Switch Activates the map lights (which are located in the sleeper ceiling lights.

  • Page 109: Fresh Air Vent

    98 INSTRUMENTS AND CONTROLS Fresh Air Vent C0029233 An air vent is provided to circulate outside air to the cab interior. Move the vent lever to the left or right to open the vent. Move the lever to the left to close the vent.

  • Page 110: Cab Air Filter

    INSTRUMENTS AND CONTROLS 99 C0029234 Cab Air Filter W8056454 To provide comfortable and clean fresh air in the cab, the heating and air conditioning system is designed with a replaceable filter. Under normal operating conditions the filter should be replaced every 6 months to ensure the efficiency of the heating and air conditioning system.

  • Page 111: Accessory Power Outlets

    100 INSTRUMENTS AND CONTROLS Accessory Power Outlets Additional 12-volt accessory power outlets are located next to the driver on the "E" panel. These cigar light-type outlets supply 12 volts of fused (20A) power when the ignition switch is turned to the ignition or accessory position. C0029236 C0029238 On chassis equipped with a sleeper cab, there are also additional power...
  • Page 112 INSTRUMENTS AND CONTROLS 101 C0029239 CAUTION Maximum amperage for all power receptacles in cab is 20 amps. Do NOT exceed maximum amperage as equipment damage may result. CB Radio Power Jack (+) Located in Headliner on Sleeper Cab; on Dashboard in Day Cab (Red) This is a 12-volt, switched battery connection.
  • Page 113 102 INSTRUMENTS AND CONTROLS C0029240 C0029241...

  • Page 114: Operation

    Whenever equipment requires adjustment, replacement, repair or lubrication, refer to the Service Manuals or contact an authorized Mack Truck Inc. 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 115: Pre-Trip Inspection Quick List

    104 OPERATION Pre-Trip Inspection Quick List Inspect the vehicle in a circular manner. Approaching the Vehicle • Check under the vehicle for oil, fuel, coolant leaks or other signs of damage. • Check body surfaces for signs of breaks or damage. Preparation •...
  • Page 116 OPERATION 105 Left Front Brake • Condition of brake drum. With brakes released, look for a noticeable gap between lining and drum. (This check cannot be made if dust covers are in place.) • Condition of brake air hose. • Check brake chamber mounting bolts and bracket. Condition of Front Axle and Steering System, Left Side •...
  • Page 117 106 OPERATION Step 3: Right Side of Cab Area Right Front Wheel • Check condition of wheel rim. Especially look for cracks, missing lockrings, bent or broken studs, clamps or lugs. • Check condition of tire: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment;...
  • Page 118 OPERATION 107 Step 4: Right Saddle Tank Area Right Fuel Tank(s) • Securely mounted and not damaged or leaking. • Fuel lines secure and not leaking. Check that shut-off valves are open. • Tank(s) full of fuel. Cap on and secure. Condition of Visible Components •...
  • Page 119 108 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. •...
  • Page 120 OPERATION 109 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. •...
  • Page 121 110 OPERATION Left Fuel Tank(s) • Securely mounted and not damaged or leaking. • Fuel lines secure and not leaking. Check that shut-off valves are open. • Tank(s) full of fuel. Cap on and secure. Battery Area • Open the battery box. Battery box securely mounted to vehicle. •...
  • Page 122 OPERATION 111 Sliding Fifth Wheel • Check that fifth wheel is not so far forward that the tractor frame will strike the landing gear during turns. Note: Refer to the trailer manufacturer’s manual for specific information on the trailer checks. Step 10: Right Side of Trailer Area Landing Gear or Dolly Area •...
  • Page 123 112 OPERATION • 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 •...
  • Page 124 OPERATION 113 • Underside guard in place: not cracked, bent or broken. Step 13: Left Rear Trailer Wheels Area Dual Wheels, One or Two Axles • Check condition of wheels and rims. Especially look for cracks, lockrings missing, bent or broken spacers, studs, clamps or lugs. •...
  • Page 125 114 OPERATION • If power operated, no air/hydraulic leaks. Spare Wheel(s) • Spare wheel securely mounted in rack with no damage to rack. • Tire and wheel condition adequate for a spare: proper size, properly inflated. Lights and Reflectors • Trailer side clearance lights: clean, operating and proper color. •...

  • Page 126: New Vehicle Break-In

    OPERATION 115 • Apply service brakes. After initial drop, pressure should hold steady, or increase slightly, with engine at idle. • Check slack adjusters and chamber pushrod travel. • Check steering wheel for excessive free play. • Check for loose items in the cab. Secure them if necessary. Step 16: Before Leaving the Parking Area •...
  • Page 127 • 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 128: Windshield Washer Reservoir

    OPERATION 117 Initial Valve Adjustment Intervals Refer to the Maintenance and Lubrication Manual (21394653) for detailed information concerning the Initial Valve Adjustment Interval. WINDSHIELD WASHER RESERVOIR As shown in the drawing below, the windshield washer reservoir is located under the hood, against the rider-side cab bulkhead. C0029836 On chassis equipped with the snowplow option, the windshield washer reservoir will be located on the back of the cab, driver-side.

  • Page 129: Hood Operation

    118 OPERATION C0029837 HOOD OPERATION Opening the Hood To open the hood, release the locking tabs on each side of the hood. C0029315 1. With the hood in the locked position, pull outward on the plastic handle and disengage the locking tab from the hood latch. 2.
  • Page 130 OPERATION 119 C0029838 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.

  • Page 131: Closing The Hood

    120 OPERATION Closing the Hood Note: Remember to remove all tools, rags and test equipment from the engine compartment before closing the hood. WARNING Before closing the hood, be sure no one is in the way of the hood’s descent. Note: The safety latch must be released (reset) before the hood will close.

  • Page 132: Locking The Hood

    OPERATION 121 Locking the Hood To lock the hood, secure the rubber hold-down straps on each side of the hood. 1. With the hood down, set the rubber strap in position and force the locking discs into the hood latch. 2.

  • Page 133: Snowplow Hood Option

    122 OPERATION Snowplow Hood Option An optional hood is available for chassis equipped with a snowplow. This hood has an opening on the driver-side which provides the operator easy access to the engine oil dipstick and the engine oil fill tube without having to raise the entire hood.

  • Page 134: Hose Tenders

    OPERATION 123 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.

  • Page 135: Doors

    124 OPERATION DOORS Standard Door Panel C0029320 Manual Locks and Windows — Passenger Side (Right) Shown 1. Manual Door Lock 4. Storage Pouch 2. Door Handle 5. Lower View Window (Passenger Side Only) 3. Door Light 6. Window Crank 1. Manual Door Lock — Push backward to lock. Push forward to unlock. The lock opening appears red when unlocked.

  • Page 136: Power Door Panel (Optional)

    OPERATION 125 Power Door Panel (Optional) C0029322 Power Locks and Windows — Driver Side (Left) Shown 1. Manual Door Lock 5. Door Handle 2. Left Side Power Window Control 6. Door Light 3. Right Side Power Window Control 7. Storage Pouch 4.

  • Page 137: Opening The Cab Door

    126 OPERATION 5. Door Handle — Lift handle to open. 6. Door Light — The door light automatically comes on when the door is opened and goes out when the door is closed. 7. Storage Pouch — Large, rigid storage pouch. Opening the Cab Door To open the door, grasp the front of the door handle and pull upward.

  • Page 138: Remote Keyless Entry - (Optional)

    OPERATION 127 REMOTE KEYLESS ENTRY — (OPTIONAL) This vehicle is equipped with a Remote Keyless Entry system. This system operates by means of a hand-held remote control that locks and unlocks the cab doors. The remote control door lock transmitters are supplied in pairs; each one is attached to a key ring.

  • Page 139: Transmitter Operations

    128 OPERATION Transmitter Operations The door transmitter has four buttons (labeled LOCK, UNLOCK, AUX and HORN) to control operation of the system. When any of the buttons is pressed, a coded Ultra-high frequency (UHF) radio signal is transmitted to the receiver in the vehicle. The transmitter must be within approximately 10 meters (33 feet) of the vehicle for the receiver to detect the coded signal.
  • Page 140 OPERATION 129 C0029324 2. Remove the battery. 3. Install a new battery with the positive (+) side down. C0029325 1. Battery, positive (+) side down 4. Align the transmitter case halves, then snap the case together. 5. Check the operation of the transmitter. Troubleshooting The following checks may be used to diagnose any problems which may arise with Remote Keyless Entry system operation.
  • Page 141 130 OPERATION 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.
  • Page 142 OPERATION 131 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.

  • Page 143: Seat Belts

    MACK vehicles manufactured on or after September 1, 1990 must have locking retractable seat belts. For all seating positions in your MACK vehicle, this type of seat belt is a combination lap and shoulder belt. This type of belt is designed to lock (prevent belt travel out of the retractor) only during sudden stops or impacts.
  • Page 144 OPERATION 133 DANGER Do NOT wear seat belt loosely. Do NOT use one belt for more than one person. 2. Make sure the clip is securely fastened into the buckle. C0029326 3. To tighten the lap portion of the combination belt, pull upward on the shoulder portion until the lap portion fits snugly.

  • Page 145: Adjustable D-Ring Shoulder Belts (If Equipped)

    134 OPERATION Adjustable D-Ring Shoulder Belts (if equipped) C0029327 The shoulder belt portion of the three-point belt is adjustable so that the belt can be adjusted to lay properly and comfortably across the shoulder. To adjust the belt, squeeze the release lock and move the belt to the desired position. The belt locks into place when the lock is released.

  • Page 146: Komfort® Latch System

    OPERATION 135 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.
  • Page 147 136 OPERATION 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.

  • Page 148: Seat Adjustment And Recline (If Equipped)

    OPERATION 137 SEAT ADJUSTMENT AND RECLINE (IF EQUIPPED) WARNING Do not adjust the driver’s seat while the vehicle is moving. After adjusting the seat and before driving off, ensure that the seat is firmly latched in position. WARNING Do not drive or ride with the seat reclined. In case of a sudden stop, a person in a reclined position may slide under the seat belt.

  • Page 149: Mirror Breakaway Strut

    138 OPERATION MIRROR BREAKAWAY STRUT The mirror breakaway strut steadys the mirror, and is designed to "break-away" should the mirror hit an object. The breakaway strut needs no maintenance, and should never need to be replaced. To re-attach the strut to the mirror bracket: 1.

  • Page 150: 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 151: 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 152: Tire Pressure Control System (If Equipped)

    OPERATION 141 TIRE PRESSURE CONTROL SYSTEM (IF EQUIPPED) The Dana® Tire Pressure Control System (TPCS) is an incredibly simple system to operate. All commands to adjust tire pressures are controlled by the driver from an easy-to-use operator control panel located in the overhead compartment above the driver.
  • Page 153 142 OPERATION C0029841 WARNING ICONS Two warning icons report operating problems. You must take immediate action to either reduce vehicle speed or check tire condition whenever these icons activate. CAUTION Failure to respond may result in tire overheating and reduced tire life or a tire blowout.
  • Page 154 OPERATION 143 C0029843 Check Tire Condition — This signal reports that one tire is at a significantly lower pressure than the others and could indicate that a tire is not holding pressure. Stop the vehicle immediately and identify the extent of tire damage. The system may be used to re-inflate the low tire if damage is determined to be minimal (e.g., a minor puncture or slow leak) by selecting RUN FLAT.
  • Page 155 144 OPERATION L/U Key (Loaded/Unloaded) — This key selects pressures appropriate for either a loaded or unloaded vehicle. HWY — For high speed travel on paved surfaces. OFF HWY — For operation on secondary roads. EMER — For selection of extremely low tire pressures to help free a stuck vehicle.
  • Page 156 OPERATION 145 C0029846 CONFIGURATION INDICATORS The tractor/trailer outline show(s) whether the vehicle is configured with a two channel (tractor or straight truck) or three channel (tractor and trailer) TPCS. RUN FLAT INDICATOR This asterisk matches the symbol on the RUN FLAT key and it indicates that the Run Flat feature is selected.
  • Page 157 146 OPERATION SELECT KEY This key allows the operator to continuously monitor one channel, or scan all of them. On power-up, the Operator Control Panel will not display any pressures ("Quiet Mode"). Pressing the SELECT key once will cause the display to scan the tire pressures (see Channel Indicators).

  • Page 158: Tire Changing Procedure

    OPERATION 147 Tire Changing Procedure CAUTION If the tire being removed is not flat, high pressure air will be released when the tire hose is disconnected from the valve stem. To minimize air loss, install the valve stem cap from the wheel valve to the tire stem to stop the flow of air from the tire upon removal of the hose.
  • Page 159 148 OPERATION WHEEL INSTALLATION Note: The tire valve stem core cannot be used on vehicles equipped with the Dana Tire Pressure Control System. Note: Reverse the above procedure for installation.

  • Page 160: Cruise Control Operation

    OPERATION 149 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 161: Disengaging Cruise Control

    150 OPERATION 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 162: 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 163: How The Engine Brake Is Activated

    152 OPERATION 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.

  • Page 164: 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 165: 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 166: 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 167 C0029333 1. Descent Speed without MACK Engine Brake Switch the MACK PowerLeash™ Engine Brake to the HIGH position, and now it is possible to descend the same grade in sixth gear to maintain a steady 35 mph at 2,000 engine rpm.

  • Page 168: 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 169 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.

  • Page 170: Brake Operation

    OPERATION 159 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 171: Automatic Slack Adjusters

    160 OPERATION 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 172: Parking Brake Operation

    OPERATION 161 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 173 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 174 OPERATION 163 • Any repairs to the steering system or front suspension such as: — Replacement of front springs — Replacement of king pins or bushings — Replacement of the steering gear — Replacement of the drag link, cross steering tube or ball sockets —...
  • Page 175 164 OPERATION WARNING Failure to disable the RSA system on a vehicle that has been modified will result in serious vehicle braking and performance issues, including unnecessary system interventions. These interventions could lead to a loss of vehicle control. In addition to disabling the system, any cab labels, such as warning and caution labels relating to the Bendix®...
  • Page 176 OPERATION 165 Enhanced Stability Program Enhanced Stability Program (ESP) is an optional system that uses existing ABS and ATC components with the addition of electronic sensors and brake valves. The system will automatically apply and release individual brakes to improve vehicle control when extreme conditions are detected. In the event a pending rollover situation is sensed, the system applies all brakes to reduce vehicle speed to lessen the possibility of rollover.

  • Page 177: Automatic Traction Control (Atc) (If Equipped)

    166 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.
  • Page 178 OPERATION 167 Heavy Mud/Snow Function (If Equipped) ATC may also include a heavy mud/snow function which allows the operator to activate ATC when additional traction is needed. This function is activated with the ATC mode switch which is located on the dashboard. The heavy mud/snow function increases available traction by increasing permissible wheel spin.

  • Page 179: Good Driving Habits

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

  • Page 180: Starting The Vehicle

    OPERATION 169 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 181: Air Starters

    170 OPERATION Air Starters On chassis equipped with an air starter, make sure that the air pressure gauge reads a maximum of 120 psi before shutting down and parking for the night. This will ensure sufficient air pressure for restarting the engine. WARNING Make sure clutch is depressed and transmission is in neutral before engaging the starter! Failure to do so could cause the vehicle to jerk forward...
  • Page 182 OPERATION 171 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 183 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 184: Engine Warm-Up

    OPERATION 173 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 185: 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 186 OPERATION 175 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 187: Cold Weather Operation

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

  • Page 188: Engine Block Heaters

    OPERATION 177 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 189: Winterfronts

    The use of any other type of device, such as a radiator cover, cardboard or similar material, is not approved by Mack Trucks, Inc. Note: The minimum operating temperature is 77°C (170°F). If a winterfront is used, a MACK-approved exhaust pyrometer must also be installed and closely monitored while the engine is in operation. CAUTION DO NOT exceed the maximum exhaust temperature listed on the pyrometer decal.
  • Page 190 OPERATION 179 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 4°C (40°F) Prohibited Available 0°C (32°F) Prohibited Available Suggested -7°C (20°F) -12°C (10°F) Suggested -18°C (0°F) -23°C (-10°F)
  • Page 191 180 OPERATION C0029339 Tractor Scale Display Your chassis may be equipped with an optional Tractor Scale System. The AW5800 on-board scale converts tractor and trailer suspension loads to an accurate on-ground weight. By comparing empty and loaded axle group weights with empty and loaded suspension pressures, the scale can be calibrated to display accurate weights for any air suspension load.

  • Page 192: Coupling A Trailer

    OPERATION 181 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.
  • Page 193 182 OPERATION 11. Inspect the coupling to ensure the trailer is properly connected. Make sure there is no space between the fifth wheel and the trailer plate and that the fifth wheel jaws have closed around the shank of the king pin. Check that the locking lever is in the "lock"...

  • Page 194: Uncoupling A Trailer

    OPERATION 183 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.
  • Page 195 184 OPERATION 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.

  • Page 196: Moving The Vehicle - General Information

    OPERATION 185 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 197: Engine Temperature

    186 OPERATION CAUTION Running the engine at a speed that is too low for the load (or grade of the road) can cause damage to the drivetrain. Shifting at the proper time will result in increased fuel efficiency, as well as a decrease in costly repairs.
  • Page 198 OPERATION 187 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.
  • Page 199 188 OPERATION C0029340 1. Normal Clutch Pedal Travel 2. Depress Pedal last 13 mm (1/2 inch) to 25 mm (1 inch) to Engage Clutch Brake (amount of clutch brake travel varies depending on the system and overall tolerances)
  • Page 200 OPERATION 189 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.
  • Page 201 190 OPERATION 1. Depress the clutch pedal and shift to NEUTRAL. 2. Release the clutch pedal and increase (downshift) or decrease (upshift) engine speed until it roughly corresponds to the road speed of the desired gear. 3. Depress the clutch pedal and complete the shift. Then release the clutch pedal.

  • Page 202: Power Take-Off (Pto) Operation

    OPERATION 191 POWER TAKE-OFF (PTO) OPERATION If the vehicle is equipped with a Power Take-Off (PTO) unit, be sure to read the following section. PTO Precautions DANGER Power Take-Off (PTO) units and related equipment can be very dangerous. Any PTO installation, repair or replacement should include a warning indicator light which indicates PTO engagement.

  • Page 203: Pto Classification

    192 OPERATION PTO Classification Rear-mounted PTO units, for MACK transmissions, are categorized according to operation. Intermittent Service — The PTO unit is operated, under load, for less than seven minutes and then allowed to cool before it is operated again.

  • Page 204: Transmission Shifting Instructions

    OPERATION 193 TRANSMISSION SHIFTING INSTRUCTIONS CAUTION The maximum safe operating oil temperature for MACK transmissions is 121°C (250°F) for mineral-based oil, and 148°C (300°F) for synthetic-based oil. Continued operation with oil above this temperature will result in rapid deterioration of the oil’s lubricating properties and is NOT recommended.

  • Page 205: Mack T306G Shifting Instructions

    194 OPERATION MACK T306G Shifting Instructions The T306G is a six-speed overgear, non-synchronized transmission designed for general highway use. Shifting is accomplished through a single shift lever using the traditional H pattern. Upshift — Start out in first gear and shift up to second, third, fourth, fifth and sixth gears, double-clutching from one gear to the next.

  • Page 206: Mack Tm308 Shifting Instructions

    OPERATION 195 MACK TM308 Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is warmed before shifting the transmission. To avoid transmission damage, do NOT change range while moving in REVERSE. Use of the clutch brake is for shifting into first and reverse gears only.
  • Page 207 196 OPERATION C0029342 TM308 TRANSMISSION RATIOS Ratios Gear (Main Box) LO Range Hi Range First Lo 17.77 Second Lo 10.94 First Hi 6.57 4.05 Second Hi Third Hi 2.54 Fourth Hi 1.57 Fifth Hi 1.00 Sixth Hi 0.71 Reverse Lo 18.36 Reverse Hi 6.79...

  • Page 208: Mack Tm308M Shifting Instructions

    OPERATION 197 MACK TM308M Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is warmed before shifting the transmission. Use of the clutch brake is for shifting into first and reverse gears only. Do not use the clutch brake to shift out of gear. Be careful not to overspeed the engine during downshifting.
  • Page 209 198 OPERATION • Select desired gear. CAUTION Vehicle operators must use extreme caution if operating a truck in the higher reverse gears. Higher reverse gears will produce high reverse speeds which may be difficult for drivers to control dependent on terrain or obstacles.
  • Page 210 OPERATION 199 C0029343 TM308M TRANSMISSION RATIOS 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...

  • Page 211: Mack Tm309 Shifting Instructions

    200 OPERATION MACK TM309 Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is warmed before shifting the transmission. To avoid transmission damage, do NOT change range while moving in REVERSE. Use of the clutch brake is for shifting into first and reverse gears only.
  • Page 212 OPERATION 201 C0029344 TM309 TRANSMISSION RATIOS 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 1.00 Fifth Hi 0.71 Sixth Hi Reverse Lo 25.67 Reverse Hi...

  • Page 213: Mack Tm309M Shifting Instructions

    202 OPERATION MACK TM309M Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is warmed before shifting the transmission. Use of the clutch brake is for shifting into first and reverse gears only. Do not use the clutch brake to shift out of gear. Be careful not to overspeed the engine during downshifting.
  • Page 214 OPERATION 203 C0029345 TM309M TRANSMISSION RATIOS 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...

  • Page 215: Mack T309, T309L And T309Lr Shifting Instructions

    204 OPERATION MACK T309, T309L and T309LR Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts. Always start in LO range. This also applies to dynamometer testing. When the truck is stationary, do NOT shift into HI range and then start moving the truck.
  • Page 216 OPERATION 205 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.
  • Page 217 206 OPERATION Gear (Main Box) LO Range HI Range 11.24 7.35 1.94 5.25 1.39 3.78 1.00 2.69 0.71 13.31 3.52 T309L TRANSMISSION RATIOS Gear (Main Box) LO Range HI Range 13.74 7.35 1.94 5.25 1.39 3.78 1.00 2.69 0.71 13.31 3.52 T309LR TRANSMISSION RATIOS Gear (Main Box)
  • Page 218 OPERATION 207 1. Position the vehicle for power take-off operation. 2. Stop the vehicle and apply the spring brakes. 3. Raise the vehicle wheels off the ground. 4. Shift the transmission to NEUTRAL. 5. Turn on PTO. 6. Place the range selector to HIGH. 7.

  • Page 219: Mack T310 Shifting Instructions

    208 OPERATION MACK T310 Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is warmed before making range shifts. Always start in LO range. This also applies to dynamometer testing. When the truck is stationary, do NOT shift into HI range and then start moving the truck.
  • Page 220 OPERATION 209 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.

  • Page 221: Mack T310M, T310Me And T310Mlr Shifting Instructions

    3.75 0.73 14.73 2.85 MACK T310M, T310ME and T310MLR Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts. Always start in LO range. This also applies to dynamometer testing.
  • Page 222 OPERATION 211 The T310M is a range-shifted transmission which has 10 forward speeds. There is a LO and HI auxiliary compound section controlled by an air-shift selector on the shifter. This compound section is equipped with a synchronizer to facilitate LO-HI range shifting. The T310M transmission also provides a multi-speed reverse feature by means of reverse gearing in the compound case which works in conjunction with LO-LO, first and second speed gears in the main box.
  • Page 223 212 OPERATION • Bring vehicle to a stop. • Move lever to NEUTRAL. • Select low range. • Select F or R as desired. • Select lowest lever gear position. • Release and depress clutch pedal. • Select desired gear. C0029348 T310M AND T310ME TRANSMISSION RATIOS Gear (Main Box)
  • Page 224 OPERATION 213 T310MLR TRANSMISSION RATIOS Gear (Main Box) LO Range HI Range Reverse LOLO 27.30 23.96 13.90 12.22 7.45 1.94 6.54 5.33 1.39 4.67 3.83 1.00 3.37 2.73 0.71 2.40 Preferred Method for Engaging T310M or T310MLR High Range Gear for Output Shaft Driven Power Take-Off Operation After positioning the vehicle for power take-off operation: 1.

  • Page 225: Mack T313-T313L-T313Lr Shifting Instructions

    214 OPERATION MACK T313-T313L-T313LR Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts. Always start in LO range. This also applies to dynamometer testing. When the truck is stationary, do NOT shift into HI range and then start moving the truck.
  • Page 226 OPERATION 215 Refer to the shift pattern and move the shift lever to LO speed gear (LO range, LO-split). Apply accelerator, engage the clutch, and accelerate to governed speed. Shift up through first, second, third and fourth speed gears, double-clutching between the gears. To continue while in fourth gear (LO-split), flip the range selector up to HI range (preselect), then move the shift lever through NEUTRAL to fifth gear.
  • Page 227 216 OPERATION To make a range shift in reverse, bring the truck to a complete stop. Flip the range selector to the range desired (preselect). Move the shift lever out of reverse through NEUTRAL, and then back into reverse again. As the lever moves through NEUTRAL, the range shift will be completed.
  • Page 228 OPERATION 217 T313, T313L AND T313LR TRANSMISSION RATIOS Gear Ratios (Main Box) Splitter Range T313LR T313 T313L 16.42 13.44 16.42 8.78 8.78 8.78 6.28 6.28 6.28 4.52 4.52 4.52 3.22 3.22 3.22 Range Shift Here 2.29 2.29 2.29 1.94 1.94 1.94 1.64 1.64...

  • Page 229: Mack T31321, T313L21 And T313Lr21 Shifting Instructions

    5. Move the shift lever to the desired main gear box ratio. 6. Release the parking brakes. 7. Release the clutch pedal to engage the clutch. MACK T31321, T313L21 and T313LR21 Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts.
  • Page 230 OPERATION 219 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.
  • Page 231 220 OPERATION 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.
  • Page 232 OPERATION 221 T31321, T313L21 AND T313LR21 TRANSMISSION RATIOS Gear Ratios (Main Box) Splitter Range T31321 T313LR21 T313L21 13.44 16.42 16.42 8.78 8.78 8.78 6.28 6.28 6.28 4.52 4.52 4.52 3.22 3.22 3.22 Range Shift Here 2.29 2.29 2.29 1.94 1.94 1.94 1.64 1.64...

  • Page 233: Mack T318, T318L And T318Lr Shifting Instructions

    222 OPERATION MACK T318, T318L and T318LR Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts. Always start in LO range. This also applies to dynamometer testing. When the truck is stationary, do NOT shift into HI range and then start moving the truck.
  • Page 234 OPERATION 223 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.
  • Page 235 224 OPERATION C0029351...
  • Page 236 OPERATION 225 T318, T318L AND T318LR TRANSMISSION RATIOS Gear Ratios (Main Box) Splitter Range T318 T318LR T318L 13.44 16.42 16.42 11.40 13.93 13.93 8.78 8.78 8.78 7.45 7.45 7.45 6.28 6.28 6.28 5.33 5.33 5.33 4.52 4.52 4.52 3.83 3.83 3.83 3.22 3.22...
  • Page 237 226 OPERATION Rear Case, Side-Mounted PTO Operating Procedures (T318, T318L and T318LR) When engaging the PTO — 1. Select LO-split using the splitter switch and select LO range using the range selector. Note: The transmission MUST be in LO range and LO-split at all times during PTO operation.
  • Page 238 OPERATION 227 Preferred Methods for Engaging T318(L)(LR) "Eighteenth" Gear (or any HI-range gear) for Output Shaft Driven Power Take-Off Operation Method #1 After positioning the vehicle for power take-off operation, and with vehicle wheels off the ground: 1. Shift the transmission to NEUTRAL. 2.

  • Page 239: Mack T31821, T318L21 And T318Lr21 Shifting Instructions

    228 OPERATION MACK T31821, T318L21 and T318LR21 Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts. Always start in LO range. This also applies to dynamometer testing. When the truck is stationary, do NOT shift into HI range and then start moving the truck.
  • Page 240 OPERATION 229 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.
  • Page 241 230 OPERATION C0029352...
  • Page 242 OPERATION 231 T31821, T318L21 AND T318LR21 TRANSMISSION RATIOS Gear Ratios (Main Box) Splitter Range T31821 T318LR21 T318L21 13.44 16.42 16.42 11.40 13.93 13.93 8.78 8.78 8.78 7.45 7.45 7.45 6.28 6.28 6.28 5.33 5.33 5.33 4.52 4.52 4.52 3.83 3.83 3.83 3.22 3.22...
  • Page 243 232 OPERATION Rear Case, Side-Mounted PTO Operating Procedures (T31821, T318L21 and T318LR21) When engaging the PTO — 1. Select LO-split using the splitter switch and select LO range using the range selector. Note: The transmission MUST be in LO range and LO-split at all times during PTO operation.
  • Page 244 OPERATION 233 Preferred Methods for Engaging T318(L)(LR)21 "Eighteenth" Gear (or any HI-range gear) for Output Shaft Driven Power Take-Off (PTO) Operation Method #1 After positioning the vehicle for power take-off operation, and with vehicle wheels off the ground: 1. Shift the transmission to NEUTRAL. 2.

  • Page 245: 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 246: Engaging The Power Divider Lockout

    OPERATION 235 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 247: All-Wheel-Drive In Gu Chassis (If Equipped)

    236 OPERATION 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. All-Wheel-Drive in GU Chassis (If Equipped) Transfer Case — The TC15 Series and TC25 Series are two-speed transfer cases designed for all-wheel-drive vehicles.
  • Page 248 OPERATION 237 Model HI Range Front Drive LO Range TC 15 Series 0.999 2.593 0.965 SHIFT TC(S)15 PATTERN TC(S)150 0.768 1.992 0.965 TC(S)151 0.999 2.593 0.838 TC(S)1510 0.768 1.992 0.838 TC(S)152 0.999 2.593 1.000 TC(S)1520 0.768 1.992 1.000 C0029904 Model HI Range LO Range Front Drive...

  • Page 249: Extended Idling And Aftertreatment System Conditioning

    238 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 250: Mack, Epa2010 Emissions Solution 239

    • Thermal Regeneration Unit (TRU) DPF (moving regeneration and parked regeneration) as well as two different mounting styles: 1. MACK Vertical Back-of-Cab DPF (both conventional DPF and TRU DPF) 2. MACK-Cap DPF, which is a space saving unit that is mounted inside the frame (conventional only) C0029353...
  • Page 251 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.
  • Page 252 Mack, EPA2010 Emissions Solution 241 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.

  • Page 253: Extended Idling And Aftertreatment System Conditioning

    242 Mack, EPA2010 Emissions Solution 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 .

  • Page 254: Exhaust Aftertreatment System

    Mack, EPA2010 Emissions Solution 243 display is available there will be no indication of an ATS conditioning event except for the automatic increase in engine speed. Exhaust Aftertreatment System GU Standard System View W2029933 ultra-pure water. Urea is a compound 1.

  • Page 255: Safety Information

    244 Mack, EPA2010 Emissions Solution 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. The system is be at extremely high temperatures designed to require very little driver during regeneration.

  • Page 256: Exhaust Aftertreatment System Components And

    Mack, EPA2010 Emissions Solution 245 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 257 246 Mack, EPA2010 Emissions Solution 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.
  • Page 258 Mack, EPA2010 Emissions Solution 247 W2055492 Horizontal SCR, full size W2055493 Horizontal SCR, compact size CAUTION Do not put diesel fuel in the Aftertreatment DEF tank. Diesel fuel, if sprayed into the hot exhaust along with the DEF, could ignite...

  • Page 259: Diesel Exhaust Fluid (Def)

    248 Mack, EPA2010 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 260 Mack, EPA2010 Emissions Solution 249 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 261 250 Mack, EPA2010 Emissions Solution Diesel Exhaust Fluid( DEF) Consumption DEF consumption is related to fuel completely, vehicle power will be reduced. consumption. A highway truck may travel When the DEF tank is refilled, the engine 225–300 miles or more on one gallon of will resume normal power.

  • Page 262: 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 263: Aftertreatment Control Module (Acm)

    252 Mack, EPA2010 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 264: Exhaust Aftertreatment System

    Mack, EPA2010 Emissions Solution 253 Exhaust Aftertreatment System Aftertreatment DPF Regeneration DPF Smart Switch– This is a three-position switch where the middle position is neutral. C0029148 DPF Smart Switch 1. Upper Position – Regeneration 3. Down Position – Inhibit Position (if...
  • Page 265 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.
  • Page 266 Mack, EPA2010 Emissions Solution 255 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.
  • Page 267 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.
  • Page 268 Mack, EPA2010 Emissions Solution 257 DPF INHIBIT ROAD SPEED LIMITING (RSL) The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen) position by the driver (if equipped). If the DPF Smart Switch remains in the locked position, the following vehicle speed limiting will occur: 1 Vehicle Moving.

  • Page 269: Driver Warnings And On Board Diagnostics (Obd)

    258 Mack, EPA2010 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 270: Instrument Cluster

    Mack, EPA2010 Emissions Solution 259 Instrument Cluster The aftertreatment icons are located in the instrument cluster per the following images. CHU Instrument Cluster W3031621 1. Malfunction Indicator 2. CHECK Lamp 3. Aftertreatment DEF Lamp (MIL) Low Lamp 4. High Exhaust 5.

  • Page 271: Malfunction Indicator Lamp (Mil)

    260 Mack, EPA2010 Emissions Solution Instrument Cluster Icons Aftertreatment icons are displayed on exhaust gas temperature during a passive the instrument cluster. There are 3 regeneration. When the HEST icon is aftertreatment icons: illuminated, do not park or operate the •...

  • Page 272: Aftertreatment Def Tank Level - Driver Warning & Inducement

    Mack, EPA2010 Emissions Solution 261 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 273: Aftertreatment Def Quality - Driver Warning & Inducement

    262 Mack, EPA2010 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 274: Misfilling Diesel Or Aftertreatment Def Tanks

    Mack, EPA2010 Emissions Solution 263 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.

  • Page 275: Scr Tampering - Driver Warning & Inducement

    264 Mack, EPA2010 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 276: Warranty And Maintenance

    Mack, EPA2010 Emissions Solution 265 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 277: 266 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 278: Turbocharger

    MAINTENANCE AND LUBRICATION 267 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 279: Cleaning Your Vehicle

    268 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 280 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 281: 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 282: Cab Interior

    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 283: Towing

    272 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 284 MAINTENANCE AND LUBRICATION 273 C0029851 C0029852 1. Towhook Access...

  • Page 285: Engine Oil Level Check

    274 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 286: Chassis Equipped With Snowplow Hood Option

    MAINTENANCE AND LUBRICATION 275 Chassis Equipped with Snowplow Hood Option An optional hood is available for chassis equipped with a snowplow. This hood has an opening on the driver-side which provides the operator easy access to the engine oil dipstick and the engine oil fill tube without having to raise the entire hood.

  • Page 287: Power Steering Reservoir

    276 MAINTENANCE AND LUBRICATION Power Steering Reservoir The Power Steering system uses only DEXRON® type automatic transmission fluid. C0029423 Power Steering Reservoir 1. Power Steering Reservoir For additional information about power steering, refer to the Maintenance and Lubrication Manual...

  • Page 288: 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 289: Fueling

    278 MAINTENANCE AND LUBRICATION FUELING DANGER DO NOT carry extra fuel containers in the cab. Fuel containers, full or empty, may leak, explode or give added fuel to a fire. Failure to follow this precaution may lead to serious personal injury or death. DANGER DO NOT smoke while fueling the vehicle.

  • Page 290: Biodiesel

    Note: Although higher concentrations are available, concentrations up to B5 (maximum) are the only blends currently approved by Mack Trucks, Inc. Note: MACK Engines are certified to comply with U.S. EPA and California Air Resources Board (CARB) emissions standards based on the use of reference test fuels commonly available in the United States and specified in this manual.

  • Page 291: B5 Approval For Mack Us10 Certified Products

    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 292: Cooling System

    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.

  • Page 293: Draining The Cooling System

    282 MAINTENANCE AND LUBRICATION C0029854 1. Expansion Tank Draining the Cooling System Whenever repairs are to be made which would require disconnection of coolant hoses, etc., the cooling system should be drained. Carefully remove the filler cap and remove all pipe plugs. Refilling the Cooling System Close all drain cocks and fill with the proper coolant mixture.
  • Page 294 MAINTENANCE AND LUBRICATION 283 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 295: Cooling System Maintenance

    284 MAINTENANCE AND LUBRICATION Cooling System Maintenance The cooling system must be maintained by performing regularly scheduled maintenance as outlined in the Maintenance and Lubrication Manual. Cold weather operations, however, place added demands on the cooling system. Prevent potential cold weather problems by performing a quick check of the cooling system as outlined below: •...
  • Page 296 MAINTENANCE AND LUBRICATION 285 C0029426 Accessory and Main Drive Belt Routing 1. Accessory and Main Drive Belt Routing MP8 Engine C0029855 Accessory and Main Drive Belt Routing...

  • Page 297: Headlights

    286 MAINTENANCE AND LUBRICATION 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. •...

  • Page 298: Wheels

    MAINTENANCE AND LUBRICATION 287 WHEELS Wheel Inspection Look at the wheels and cap nuts. Inspect them for evidence of cap nut looseness. Rust streaks from the cap nut ball seat are an indication of looseness. Refer to the Maintenance and Lubrication Manual for complete procedures concerning wheel inspection and wheel nut tightening.

  • Page 299: Tires

    288 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 300 MAINTENANCE AND LUBRICATION 289 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 301 290 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 302: Battery

    MAINTENANCE AND LUBRICATION 291 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 303 292 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 304: Electrical

    MAINTENANCE AND LUBRICATION 293 ELECTRICAL Circuit Breaker and Relay Panels The electrical equipment cover for this vehicle is located in the middle of the dash under the top cover. The cover panels are fastened with screws. Most relays and fuses are accessible from under the top cover.
  • Page 305 294 MAINTENANCE AND LUBRICATION C0029434 1. Front 2. Back...
  • Page 306 MAINTENANCE AND LUBRICATION 295 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 307: Electrical Grease

    296 MAINTENANCE AND LUBRICATION 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 308 MAINTENANCE AND LUBRICATION 297 Cab Circuit Protection #28 — 20A #29 — 10A #30 — 20A #31 — 15A Htd. seats EMS #1 Relay Opt. Ign. Power Auto shift trans. Coil/Short Range Sw., Spare or spare Wireless #53 — 15A #60 —...
  • Page 309 298 MAINTENANCE AND LUBRICATION Engine Circuit Protection (V-MAC IV) #32 — 30A #33 — 30A #34 — 30A #35 — 30A Spare Body Bld. Trailer Stop Lps. Reverse/Neutral Cab & Trailer Power Clearance Lps. #36 — 15A #37 — 30A #38 —...

  • Page 310: Electrical Accessory Connection Points

    Electrical Accessory Connection Points 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.
  • Page 311 Power Jack (-) This is a ground connection. It is to be used as a power return connection for the vehicle’s CB radio. Body Builder Connectors The Mack® Granite™ GU axle back chassis offers two optional body builder interface connectors located inside the frame rail on the right-hand side of the chassis behind the cab.
  • Page 312 MAINTENANCE AND LUBRICATION 301 C0029856 Inside the Frame Rail 1. Upper Connector 3. Lower Connector 2. Ground Stud C0029857 Inside the Back of the Frame Rail 1. 5-Way Lighting Connector...
  • Page 313 302 MAINTENANCE AND LUBRICATION These connectors provide connections to the following circuits: Upper Connector: Electrical Connection Fused amps • 12V battery feed • 12V battery feed • 12V Ignition feed • 12V Ignition feed • Reverse Power feed/Neutral Power feed •...
  • Page 314 MAINTENANCE AND LUBRICATION 303 Lower Connector: Electrical Connection Fused amps • Back Up Lamp Signal • Dash Mounted 12V Battery Switch** • Dash Mounted 12V Ignition Switch** • PTO 1 & PTO 2 Signals • Speed Control Input • Set Speed Input •...

  • Page 315: Metric Conversions

    304 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 316 METRIC CONVERSIONS 305 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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