Mack CHM 2010 Operator'S Handbook Manual Download

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184 Mack, Emissions Solution

W8056653

Summary of Contents for CHM 2010

Page 1: ...Mack RH Drive Australia 21630923 21630923 21630923 November 2010 Mack Trucks 2010 Mack RH Drive CSM CMM CHM CLX CXX Australia Mack RH Drive CSM CMM CHM CLX CXX Australia...

Page 2: ......

Page 3: ...plaints 12 Addresses 13 SAFETY INFORMATION 14 SAFETY STATEMENT 14 ADVISORY LABELS 15 Advisory Label Definitions In Handbook 16 Advisory Label Locations On Vehicle 17 mDRIVE Transmission Label 24 CAB E...

Page 4: ...pening the Hood 81 Closing the Hood 82 Locking the Hood 82 HOSE TENDERS 83 DOORS 84 Standard Door Panel 84 Locking the Cab Door 86 Power Window Regulators 86 REMOTE KEYLESS ENTRY OPTIONAL 87 Transmitt...

Page 5: ...old Weather Starting Tips 132 COUPLING A TRAILER 133 UNCOUPLING A TRAILER 134 MOVING THE VEHICLE GENERAL INFORMATION 136 Braking 136 Shifting 136 Engine Temperature 137 Clutch If Equipped 138 POWER TA...

Page 6: ...dicator Lamp MIL 188 Aftertreatment DEF Tank Level Driver Warning Inducement 189 Misfilling Diesel or Aftertreatment DEF Tanks 190 SCR Tampering Driver Warning Inducement 191 Warranty and Maintenance...

Page 7: ...Tyres 206 BATTERY 208 Jump Starting Engine 209 ELECTRICAL 210 Circuit Breaker and Relay Panels 210 mDRIVE Relay Center 213 Electrical Grease 214 Circuit Protection Charts 215 Electrical Accessory Con...

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Page 9: ...MACK model is available for a wide range of applications Because of this versatility drivetrains and components vary and operating instructions may differ from one model to another While every effort...

Page 10: ...rovide the driver with all relevant information concerning the daily operation of this vehicle Please read it thoroughly pay particular attention to advisory labels that have been included to draw att...

Page 11: ...logs fault tables trip summaries For a complete description of the V MAC IV system refer to the applicable V MAC IV Vehicle Management and Control with Co Pilot Display Operator s Guide which is supp...

Page 12: ...vided 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...

Page 13: ...CTION 5 The VIN Label Special Ratingis located on the driver side door jamb below the latch striker plate W8061401 The VIN Label is located on the driver side door jamb below the latch striker plate W...

Page 14: ...ld C0032621 In compliance with the emissions standards requirements an engine exhaust emissions control sticker is affixed to one of the engine valve covers for all MACK engines This sticker provides...

Page 15: ...be located on the gear housing W8061484 On Cummins ISX engines the engine dataplate is located on the engine rocker level cover but also may be located on the gear housing W8061485 Transmission Identi...

Page 16: ...the rear right side of the main case near the lower end C0032624 All Eaton Fuller transmission identification plates are located on the front left side of the main case C0032625 The MACK carrier asse...

Page 17: ...toward the carrier C0032627 The Eaton Spicer carrier assembly serial number is located on the left side of the forward carrier and the top of the rear carrier C0032628 The MERITOR rear axle identifica...

Page 18: ...ITOR carrier assembly serial number is located on the left side of the forward carrier and the top of the rear carrier C0032630 The SISU carrier assembly serial number is located on the top center of...

Page 19: ...hicle safety standards in effect at the time of manufacture Tractor air systems are designed for operation as a tractor only and truck air systems are designed to be operated as a truck only If a trac...

Page 20: ...lso help you plan ahead to keep your operation running efficiently by scheduling routine maintenance and lubrication service or by locating the nearest MACK dealership Questions and Complaints Your sa...

Page 21: ...100 Woodridge IL 60517 TEL 630 910 3330 FAX 630 910 3331 Southwestern and Western Regions 5605 N MacArthur Blvd 550 Mail P O Box 165408 Irving TX 75016 5408 TEL 972 518 1614 FAX 972 550 0389 Canada Ex...

Page 22: ...mes could leak into the cab area and death can result On a regular basis inspect the exhaust system for leaks and repair any leakage DANGER Driver attitude is the most important part of any effective...

Page 23: ...fan when engine is running Fan may start to rotate at high speed without warning ADVISORY LABELS Throughout this book you will find paragraphs labeled Danger Warning Caution Note and Service Hint Dang...

Page 24: ...ar throughout the manual DANGER Danger indicates an unsafe practice that could result in death or serious personal injury Serious personal injury is considered to be permanent injury from which full r...

Page 25: ...SAFETY INFORMATION 17 Advisory Label Locations On Vehicle Labels Found on Chassis C0032631...

Page 26: ...18 SAFETY INFORMATION W8061742...

Page 27: ...SAFETY INFORMATION 19 C0032633...

Page 28: ...20 SAFETY INFORMATION W8061397...

Page 29: ...SAFETY INFORMATION 21 Labels Found on Driver Side Sun Visor W8061402...

Page 30: ...22 SAFETY INFORMATION Labels Found on Passenger Seat Base C0032636 Labels Found on Coolant Tank C0032637 C0032638 C0032640...

Page 31: ...Refrigerant Label The servicing caution label 4MR3283M is located under the hood behind the receiver dryer bracket C0032642 Diesel Particulate Filter The warning label 21550677 is located in the cab o...

Page 32: ...ion located on the dash next to the mDRIVE gear selector It is extremely important that this information is read and understood before the vehicle is operated Note For Australian vehicles the operatin...

Page 33: ...d be cleaned off to prevent slipping During cold wet conditions when ice slush or snow may accumulate on the cab doorstep and other external surfaces extra caution must be observed when entering or ex...

Page 34: ...intain a firm grip on the handholds and or steering wheel and raise your other foot to the top step See figure 2 3 While still gripping the handholds and or steering wheel raise one foot to the cab fl...

Page 35: ...SAFETY INFORMATION 27 C0032643...

Page 36: ...n the inside handhold with the right hand Bring the left foot to the cab floor Then bring your right foot inside the cab and sit down See figure 4 Exit To exit follow the illustrations in reverse orde...

Page 37: ...SAFETY INFORMATION 29 C0032645...

Page 38: ...the event of an accident For additional information on the operation of doors and locks refer to the OPERATION section of this handbook SEAT BELTS DANGER Seat belts should always be secured BEFORE th...

Page 39: ...heard 2 Make sure the clip is securely fastened into the buckle 3 To tighten the lap portion of the combination belt pull upward on the shoulder portion until the lap portion fits snugly The belt sho...

Page 40: ...32 SAFETY INFORMATION C0032646 Unfastening Seat Belt Push down on the button to release the belt...

Page 41: ...ng 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 ten...

Page 42: ...el of blades Install new refills for any blades that are cracked brittle torn or coated with road oil along the wiping edge Windshield Washers Check operation of windshield washer Inspect system hoses...

Page 43: ...ich will demist cab mirrors Heated mirrors eliminate the need to pull off the highway and stand on the roadside to clean the mirrors during poor driving conditions C0032648 Air Horn Shield Installatio...

Page 44: ...t includes red reflector triangles and can be stored in the following locations Passenger floor next to the seat In the sleeper cab tool box Fire Extinguisher Optional Your vehicle may be equipped wit...

Page 45: ...S AND CONTROLS 37 CAB INTERIOR W8061336 1 Instrument Panels 4 Tilt Control Pedal 2 Cab Climate Control Panel 5 Hazard Switch Turn Signal Flash HI LO Beam and Flash to Pass 3 Foot Pedals 6 Co Pilot con...

Page 46: ...een turn signals Flashing Red hazard condition involving the safety of personnel Steady Green system in operation Steady Red warning immediate action required Amber early warning such as low fuel or A...

Page 47: ...INSTRUMENTS AND CONTROLS 39 INSTRUMENT PANEL GAUGE LAYOUT C0032654...

Page 48: ...TROLS Panel A SCR C0032656 1 Manifold Pressure Gauge If Equipped 4 Exhaust Pyrometer If Equipped 2 Oil Pressure Gauge 5 Transmission Oil Temperature Gauge If Equipped 3 Engine Water Temperature Gauge...

Page 49: ...NTROLS 41 Panel A DPF C0032656 1 Manifold Pressure Gauge If Equipped 4 Exhaust Pyrometer If Equipped 2 Oil Pressure Gauge 5 Transmission Oil Temperature Gauge If Equipped 3 Engine Oil Temperature only...

Page 50: ...cator Green 11 Check Lamp Amber 26 Bendix Adaptive Cruise Control ACC Indicator Red 12 High Beams Indicator Blue 27 Reverse Indicator Amber 13 Parking Brake Indicator Red 28 Automatic Traction Control...

Page 51: ...dicator Lamp MIL Amber 25 Right Turn Signal Indicator Green 11 Check Lamp Amber 26 Bendix Adaptive Cruise Control ACC Indicator Red 12 High Beams Indicator Blue 27 Reverse Indicator Amber 13 Parking B...

Page 52: ...44 INSTRUMENTS AND CONTROLS 19 Basic Display or Co Pilot If Equipped 34 Tachometer 20 Water in Fuel Indicator Amber If Equipped...

Page 53: ...C C0032660 35 Air Application or Air Suspension Gauge If Equipped 38 Secondary Air Pressure Gauge 36 Front Rear Axle Oil Temperature Gauge If Equipped 39 Primary Air Pressure Gauge 37 Rear Rear Axle...

Page 54: ...estriction Indicator If Equipped 43 Optional Switch 51 Accessory Power Outlet 44 Optional Switch 52 Radio Box 45 Optional Switch 53 Mic 46 Heated Mirror Defrost Switch 54 Cab Climate Control 47 Engine...

Page 55: ...Switch 59 Parking Brake Valve 68 Wiper Switch 60 Optional Switch 69 Optional Switch 61 Trailer Air Supply Valve 70 Optional Switch 62 Optional Switch 71 Optional Switch 63 Optional Switch 72 Power Mi...

Page 56: ...estriction Indicator If Equipped 43 Optional Switch 51 Accessory Power Outlet 44 Optional Switch 52 Radio Box 45 Optional Switch 53 Mic 46 Heated Mirror Defrost Switch 54 Cab Climate Control 47 Engine...

Page 57: ...ction of Optional Switches page 58 for a description of the optional switches listed in alphabetical order 1 Manifold Pressure Gauge If Equipped Measures the charge air boost pressure in the intake ma...

Page 58: ...r reduce engine power If operating in cold climates with a winterfront open the winterfront 5 Transmission Oil Temperature Gauge If Equipped Indicates transmission oil temperature CAUTION The maximum...

Page 59: ...mission Amber A amber tell tale light that illuminates when transmission oil temperature reaches a pre determined level depending on transmission make and model indicating an overheat condition or It...

Page 60: ...ge tank is below the specified level Stop and add coolant Use typical warnings etc for filling coolant 19 CO PILOT Co Pilot is an in dash computer that allows the vehicle operator to monitor informati...

Page 61: ...able materials vapors or structures 32 Fuel Gauge Registers the fuel level in the supply tank s 33 Speedometer Indicates road speed in miles and or kilometers per hour 34 Tachometer Indicates engine s...

Page 62: ...service brakes while vehicle is in motion Do not leave the vehicle while hand control brake is applied 42 Optional Switch Refer to Function of Optional Switches page 58 43 Optional Switch Refer to Fu...

Page 63: ...brakes if equipped 60 Optional Switch Refer to Function of Optional Switches page 58 61 Trailer Air Supply Valve Red octagonally shaped knob Pull to apply trailer emergency brakes Push to pressurize...

Page 64: ...page 58 71 Optional Switch Cummins Refer to Function of Optional Switches page 58 71 Latch Switch mDRIVE 72 Power Mirror Switch Controls the power mirrors 73 Optional Switch Refer to Function of Optio...

Page 65: ...can also use this port with the USB style MP3 players AUX and USB together Use both ports together for IPOD control A special cable is required for this function Once the IPOD is connected it will dis...

Page 66: ...Power Switch 10 5th Wheel Slide Switch 3 Air Suspension Control Switch 11 Inside Outside Air Switch 4 Automatic Traction Control Switch 12 Load Light Switch 5 Body Warning Lamp 13 Mirror Defrost Swit...

Page 67: ...amp 4 Right Hand Only Door Lock Switch 10 Vent Fan Switch 5 Right Hand Only Window Lift Switch 11 Windshield Defrost Switch 6 Blank Switch The following optional switches listed in alphabetical order...

Page 68: ...roperly connected After the trailer has been coupled and the trailer landing gear has been raised make sure that the 5th wheel jaws have properly engaged the trailer king pin and there is no gap betwe...

Page 69: ...sses the top of the rocker switch the heavy mud snow function ATC indicator lamp blinks continuously The ATC lamp stops blinking when the ATC mode switch is pressed again or ignition key cycled Engine...

Page 70: ...to activate the rotating beacon light Push the bottom to turn light off Strobe Switch Press the top of the switch to turn the strobe light on Push the bottom of the switch to turn light off Telma Rear...

Page 71: ...ntrols fan speed from OFF to 4 highest speed 2 Temperature Control Knob Controls the temperature of the air in the cab from COOL far left to HOT far right 3 Mode Selection Knob Controls the direction...

Page 72: ...Button Selects the cab intake air between fresh air from outside the cab and recirculated air inside the cab Note For maximum air conditioner performance select recirculated air 5 Air Conditioner ON...

Page 73: ...C0032679 1 Light Control Knob 2 Panel Dimmer Switch With the light control knob in the left position all lights are off With the knob in the middle position the parking lights and interior panel ligh...

Page 74: ...STRUMENTS AND CONTROLS LOWER CONSOLE PANEL The lower console panel is located under the Cab Climate Control area of the middle dash C0032681 1 Accessory Power Outlet 3 Cigar Lighter 2 Ashtray 4 Cup Ho...

Page 75: ...ttempting to move the vehicle to avoid losing control of the vehicle Adjusting Tilt and Telescope Push down on the foot pedal located at the right kick panel to adjust the wheel to any position within...

Page 76: ...68 INSTRUMENTS AND CONTROLS C0032684...

Page 77: ...andle in Right turn position and cancel of hazard warning 2 Handle in Left turn position and cancel position of hazard warning 3 Lift handle for headlight dimmer 4 Push for courtesy flashing of High b...

Page 78: ...3 Up Down 2 Enter Navigation of Co Pilot Menu ESC BUTTON The ESC Escape button on the stalk switch takes the Co Pilot back to the previous screen or level in the menu Note The ESC button does not fun...

Page 79: ...ms Sometimes these buttons are used to enter information into the displays Up Button Once at the top of the menu items that can be selected pressing the Up button will take the display to the last ite...

Page 80: ...down You must hold the pedal down while adjusting When the adjustment is complete release the pedal 2 Accelerator Pedal Depress to increase engine vehicle speed release to decrease engine vehicle spee...

Page 81: ...driver side and on the passenger side the dome light will come on when the cab door is opened and go off when it is closed Push the switch up to turn the dome light on when the doors are closed for ei...

Page 82: ...e overhead console Accessory Power Outlets Additional 12 volt accessory power outlets are located on the dashboard One is located next to the radio and the other is located below the radio see figures...

Page 83: ...INSTRUMENTS AND CONTROLS 75 C0032873 CAUTION Maximum amperage for all power receptacles in cab and sleeper is 15 amps Do NOT exceed maximum amperage as equipment damage may result...

Page 84: ...rm the following inspections WARNING To avoid serious injury do NOT step on fuel tank battery box frame etc unless adequate slip resistant surfaces and handholds are provided Fluids Engine oil Engine...

Page 85: ...ghts Reflectors Replace defective and burned out bulbs Replace broken lenses and reflectors Gauges and Instruments Air pressure gauge Oil pressure gauge Temperature gauge Voltmeter Component Operation...

Page 86: ...s must be filled to the correct level DO NOT OVERFILL Note Oil and filter change intervals in this manual pertain to components built by MACK Trucks For information concerning oil and oil filter chang...

Page 87: ...clearance Although this quality built vehicle has been inspected lubricated and adjusted at the MACK Trucks Assembly Plant an occasional air oil or coolant leak may develop Quick action to correct the...

Page 88: ...80 OPERATION WINDSHIELD WASHER RESERVOIR As shown in the drawing below the windshield washer reservoir is located under the hood against the passenger cab bulkhead C0032874...

Page 89: ...ition pull outward on the plastic handle and disengage the locking tab from the hood latch 2 Swing the rubber strap up and out of the way 3 Repeat this procedure on the other side of the hood Note Whe...

Page 90: ...uired to open or close the hood NEVER take both feet off the ground to tilt the hood Keep at least one foot on the ground to avoid a slip or fall Closing the Hood Note Remember to remove all tools rag...

Page 91: ...OPERATION 83 C0032877 CAUTION Be sure the hood is latched securely If the latch is not completely engaged the hood could open during operation and cause vehicle damage HOSE TENDERS C0032878...

Page 92: ...the tractor hose tenders hose hanger towel bar pogo stick etc to prevent them from tangling in the driveline DOORS Standard Door Panel C0032879 Manual Locks and Windows Passenger Side Left Shown 1 Ma...

Page 93: ...d goes out when the door is closed 4 Storage Pouch Large rigid storage pouch 5 Lower View Window Provides safe viewing of low lying obstacles on construction sites 6 Window Crank Turn counterclockwise...

Page 94: ...uch Large rigid storage pouch Locking the Cab Door The doors can be locked using the manual door lock item 1 in the illustration or a power door lock switch item 4 in the illustration Power door lock...

Page 95: ...rs each one is attached to a key ring C0032881 Each transmitter is powered by a 3 volt battery and is water resistant Information concerning battery replacement troubleshooting and programming the tra...

Page 96: ...oor will unlock and the lights will flash twice indicating that the door is unlocked The dome light will be on for 30 seconds upon unlocking the door by remote Pushing the UNLOCK button a second time...

Page 97: ...quivalent Replace the battery as follows 1 Open the transmitter by inserting a dime between the two halves of the transmitter case near the key ring hole and twisting C0032882 2 Remove the battery 3 I...

Page 98: ...check the operation of all transmitters at each point If one transmitter does not operate at some point where another transmitter does operate replace the battery in the transmitter that does not ope...

Page 99: ...the transmitter button until the module advances to your desired setting Press Transmitter Button One Chirp LED One Pulse Factory Default Setting Two Chirps LED Two Pulses The Remote function can oper...

Page 100: ...o maintenance and should never need to be replaced To re attach the strut to the mirror bracket 1 Push mirror bracket forward as far as it will go 2 Align end of strut with slot in receptacle 3 Pull b...

Page 101: ...engine above the governed speed Operate in a gear low enough to allow the engine to accelerate to or maintain governed speed when applying the throttle WARNING Misuse or modification of a turbocharger...

Page 102: ...3 Peak Horsepower MP8 Used as an Example MACK POWERLEASH ENGINE BRAKE IF EQUIPPED Engines may be equipped to be PowerLeash upgradeable These engines will be equipped with PowerLeash camshaft These eng...

Page 103: ...ine brake converts the engine to a retarding device it should NOT be used on wet or slippery roads if the vehicle has a single driving axle or if it has tandem driving axles that are lightly loaded Us...

Page 104: ...UTION Engine Stalling and potential engine damage can result from operation of the engine brake at cold oil temperatures Vehicles equipped with an Engine Brake have also been equipped with a V MAC con...

Page 105: ...emporary increase of vehicle speed if travelling downhill The operator will experience the same momentary loss of engine braking as is experienced when downshifting a conventional manual transmission...

Page 106: ...ividual switch functions are as follows Latch Mode Pressing LATCH activates the LATCH mode In this mode the engine brake activates whenever zero 0 pedal is applied The LATCH mode will only function wi...

Page 107: ...OPERATION 99 W4059732 Control Switch W4059733 Mode Switch...

Page 108: ...brake must be applied independent of Grade Gripper to hold the vehicle on a grade for an extended period of time Failure to follow this instruction can result in loss of vehicle control and serious pe...

Page 109: ...n a greater than 2 percent incline or decline Gear selector keypad is pressed to adjust to the D mode on an incline or R mode on a decline Service brake is applied ABS is functioning normally There ha...

Page 110: ...ically be deactivated by depressing either the accelerator or the clutch or if the engine speed drops below 900 rpm As soon as all of the engine brake active conditions are again true taking your foot...

Page 111: ...your V MAC IV Vehicle Management and Control with Co Pilot Display Operator s Guide for more information about this option Your local MACK dealer can change the current selection The engine brake s ab...

Page 112: ...nditions before using it in difficult or hazardous driving conditions such as steep descents or slippery roads Of course there is no substitute for driver training by a qualified specialist The follow...

Page 113: ...y adequate to control vehicle speed in situations where the roadway is relatively flat or has modestly graded rolling hills and if total vehicle weight is light C0032887 As grades and vehicle weight i...

Page 114: ...tablished for a given descent The control speed is the vehicle speed at which the retarding forces of air drag rolling resistance and engine brake power are equally balanced by the natural force of gr...

Page 115: ...necessary to occasionally apply the service brakes to maintain a safe vehicle speed and to avoid overspeeding the engine DANGER As with any vehicle regular and excessive application of the service bra...

Page 116: ...onditions are safe for testing tractability switch the MACK PowerLeash Engine Brake to the LOW position If the vehicle shows any signs of loss of control ABS activation or vehicle swerving for example...

Page 117: ...lay Operator s Guide C0035366 Speed Control Switches Cruise Control Engaging Cruise Control The speed control functions of the vehicle management and control V MAC IV system are very similar to the cr...

Page 118: ...ly manufactured vehicles and vehicles on which the VECU has been reprogrammed Note For vehicles manufactured prior to August 11 2008 the VECU has been reprogrammed Once the above conditions are satisf...

Page 119: ...be made without the use of the clutch while in the cruise control mode Failure to use the clutch will cause the engine speed RPM to increase to the high idle limit which may cause severe powertrain da...

Page 120: ...ch is pressed The new vehicle speed is set when the switch is released Press the DECEL switch to decelerate the vehicle The vehicle will decelerate for as long as the DECEL switch is pressed The new v...

Page 121: ...This method will disengage the cruise control while the clutch is disengaged and will resume the speed control when the clutch is re engaged This programmable option provides for automatic resume afte...

Page 122: ...n the system memory This mode is primarily intended for general PTO applications and engine warm up Note Brake conditions are configurable but the standard setting is park brake on and service brake o...

Page 123: ...mount default setting is 50 RPM VSC can also be programmed for Auto Set mode When enabled simply move the Speed Control switch to the ON position and activate a customer defined switch usually setting...

Page 124: ...top gear road speed limit The purpose of this option is to encourage the operator to operate the vehicle in top gear where the optimum fuel economy can be achieved There are two programmable top gear...

Page 125: ...ediately pop out in the event of a trailer breakaway or sudden trailer air line failure which will apply the trailer spring brakes In the event of a slow leak in the trailer air system the trailer sup...

Page 126: ...n as possible to have the problem investigated and corrected DANGER Automatic slack adjusters should not be manually adjusted in an effort to correct excessive pushrod stroke because this condition in...

Page 127: ...the tractor parking brake system alone ALWAYS use the tractor and trailer parking brake systems together ALWAYS apply the parking brakes when parking and make sure the parking brakes are holding the...

Page 128: ...second When towing a trailer watch the trailer through the mirrors Adjust brake application as necessary to keep the combination in a straight line Make sure the trailer follows the tractor properly A...

Page 129: ...ever the following repairs require recalibration of the SAS 60 sensor after the repair has been made Removal and reinstallation or replacement of the SAS 60 sensor CAUTION Installation of an aftermark...

Page 130: ...cessary 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 AB...

Page 131: ...hicle speedometer odometer settings are required the Advanced EC 60 ECU must be reprogrammed with the new values by a qualified technician Enhanced Stability Program Enhanced Stability Program ESP is...

Page 132: ...stationary Brake pedal fully depressed 2 Operate the new equipment under all starting running and shutdown conditions 3 Listen for signs of air exhausting from ABS modulator valves which is an indica...

Page 133: ...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 mu...

Page 134: ...ey 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...

Page 135: ...ngine has started warm the engine until the coolant temperature reaches normal operating range 77 C to 107 C 170 F to 225 F Once the engine reaches this temperature it can be operated in a normal fash...

Page 136: ...with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seriously injured Before turning on the ignition be sure that no one is near...

Page 137: ...ed at or very near normal operating temperature where efficient combustion takes place When the engine is operated unloaded lightly loaded i e stop and go operations PTO operations or periods of exten...

Page 138: ...dle three minutes before shutdown in order to stabilize the temperature of all engine parts Quick shutdowns can cause engine damage and prevent the turbocharger from being properly lubricated CAUTION...

Page 139: ...n until the timer reaches zero If a pyrometer is installed the idle cooldown function will use the pyrometer reading shutting the engine down when the temperature drops below 232 C 450 F or after 3 5...

Page 140: ...Allow about two minutes between attempts at starting the vehicle this allows the starter to cool and the batteries to re energize Note Always make sure that the battery is fully charged in cold weathe...

Page 141: ...ailer slowly until the trailer king pin engages Back slowly to avoid hitting the king pin too hard and stop as soon as the king pin is locked into the fifth wheel 7 If equipped with an air suspension...

Page 142: ...ifth wheel jaws Apply the tractor parking brakes while still backing against the king pin so the combination will be held with pressure off the fifth wheel jaws 4 Block the trailer wheels to prevent t...

Page 143: ...the landing gear collapse or sink into the ground 11 Place the transmission in neutral and apply the parking brakes 12 Inspect the parked trailer to make sure the ground is supporting the trailer and...

Page 144: ...Allowing the engine to lug causes excessive strain on the engine which could damage pistons rings cylinder walls or bearings However be sure not to overspeed the engine DANGER Always select the proper...

Page 145: ...ith high rear axle loads a torque limiting device should be used This device limits the amount of fuel that can be delivered to the engine and prevents overloading of drivetrain components while in ex...

Page 146: ...ng Instructions for specific procedures 4 Release the parking brake CAUTION If the Parking Brake indicator is on do NOT attempt to move the vehicle because driveline damage may result 5 Engage the clu...

Page 147: ...the way to the floor the clutch brake is applied when the clutch pedal is fully depressed the last one inch of travel past normal pedal travel Note When the clutch is disengaged a slight but definite...

Page 148: ...ift Then release the clutch pedal 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...

Page 149: ...f the PTO output rated torque horsepower Side Mounted PTO Locations The first choice location for Side Mounted PTOs is either of the PTO openings on the main box The second choice which is the compoun...

Page 150: ...must be completely stopped before being shifted from REVERSE to any forward speed and vice versa CAUTION Never coast with the transmission in neutral Never coast with the clutch depressed Shifting Ins...

Page 151: ...in the standard manner Always remember however to double clutch whether moving up or down through these gears Reverse gear can be used in LO range only Upshift With the shift lever in NEUTRAL flip th...

Page 152: ...Be careful not to overspeed the engine during downshifting Damage to powertrain components may result Reverse Reverse can be used in LO only To make a range shift in reverse bring the truck to a compl...

Page 153: ...OPERATION 145 C0032895 T310 TRANSMISSION RATIOS Ratios Gear Main Box LO HI 1 6 13 81 2 67 2 7 10 05 1 94 3 8 7 18 1 39 4 9 5 17 1 00 5 10 3 75 0 73 R R 14 73 2 85...

Page 154: ...LO LO and LO positions in LO range for this transmission are designed for use in off highway and slow moving operations such as curb pouring material spreading heavy load steep grade REVERSE is used...

Page 155: ...the synchronizer may result Reverse is used in LO range only To avoid transmission damage when shifting Forward to Reverse or Reverse to Forward Bring vehicle to a stop Move lever to NEUTRAL Select lo...

Page 156: ...OPERATION C0032896 T310M AND T310ME TRANSMISSION RATIOS Gear Main Box LO Range HI Range Reverse LO LO 17 35 15 22 LO 11 40 10 00 1 5 7 45 1 94 6 54 2 6 5 33 1 39 4 67 3 7 3 83 1 00 3 37 4 8 2 78 0 73...

Page 157: ...ven Power Take Off Operation After positioning the vehicle for power take off operation 1 Shift the transmission to NEUTRAL 2 Engage power take off drive 3 Move range selector to HI range 4 Disengage...

Page 158: ...s through ALL gears assume that the vehicle has a full load and will climb a slight grade To prepare for moving the vehicle position the shift lever in NEUTRAL select LO split using the splitter switc...

Page 159: ...ever and splitter in the normal manner until you reach LO speed gear LO range LO split To downshift from HI split to LO split in the same gear as engine speed falls move the splitter to LO preselect t...

Page 160: ...152 OPERATION C0032897...

Page 161: ...LO LO 6 28 6 28 6 28 2 HI LO 5 33 5 33 5 33 3 LO LO 4 52 4 52 4 52 3 HI LO 3 83 3 83 3 83 4 LO LO 3 22 3 22 3 22 4 HI LO 2 73 2 73 2 73 Range Shift Here 5 LO HI 2 29 2 29 2 29 5 HI HI 1 94 1 94 1 94 6...

Page 162: ...ound NEUTRAL control valve to the ON position which moves the synchro clutch to a NEUTRAL position 6 Engage the PTO 7 Move the main box shift lever to the desired ratio 8 Release the clutch pedal to e...

Page 163: ...ansmission range clutch engagement is heard 6 Disengage the engine clutch 7 Select 18th speed gear for T318LR 8 Engage the clutch when power take off operation is desired After positioning the vehicle...

Page 164: ...purposes of explaining the shifting procedures through ALL gears assume that the vehicle has a full load and will climb a slight grade To prepare for moving the vehicle position the shift lever in NEU...

Page 165: ...Continue downshifting using the shift lever and splitter in the normal manner until you reach LO speed gear LO range LO split To downshift from HI split to LO split in the same gear as engine speed fa...

Page 166: ...158 OPERATION C0032898...

Page 167: ...2 LO LO 6 28 6 28 6 28 2 HI LO 5 33 5 33 5 33 3 LO LO 4 52 4 52 4 52 3 HI LO 3 83 3 83 3 83 4 LO LO 3 22 3 22 3 22 4 HI LO 2 73 2 73 2 73 Range Shift Here 5 LO HI 2 29 2 29 2 29 5 HI HI 1 94 1 94 1 9...

Page 168: ...ompound NEUTRAL control valve to the ON position which moves the synchro clutch to a NEUTRAL position 6 Engage the PTO 7 Move the main box shift lever to the desired ratio 8 Release the clutch pedal t...

Page 169: ...ansmission range clutch engagement is heard 6 Disengage the engine clutch 7 Select 18th speed gear for T318L R 21 8 Engage the clutch when power take off operation is desired After positioning the veh...

Page 170: ...iers 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 thro...

Page 171: ...cle to engage the power divider lockout The lockout may be engaged while the vehicle is moving at less than 18 km h as long as the wheels are not spinning CAUTION Do not engage the power divider locko...

Page 172: ...Note A lockout indicator lamp will remain lit as long as the lockout is engaged This is to remind the driver to release the lockout as soon as normal traction is regained 3 When driving conditions pe...

Page 173: ...il and Ultra Low Sulfur Diesel ULSD fuel WARNING The Diesel Particulate Filter DPF on this vehicle may be damaged by any immersion in water and void warranty Do not allow water to enter the DPF CAUTIO...

Page 174: ...on Depending on how the vehicle is set up regeneration can occur while the vehicle is being driven referred to as a moving regeneration or when the vehicle is parked and idling referred to as a parked...

Page 175: ...ack Emissions Solution 167 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 176: ...a reactant that s key to the SCR process It s a nontoxic ultra pure solution of urea and ultra pure water Urea is a compound of nitrogen that turns to ammonia when heated It is used in a variety of in...

Page 177: ...ill increase during a parked regeneration When parking the vehicle to perform a parked regeneration keep away from any flammable materials vapors or structures DANGER Exhaust gases and components can...

Page 178: ...aftertreatment system which converts NOx in the exhaust stream into harmless gases Modern diesels already use exhaust aftertreatment systems called diesel particulate filters to control emissions of a...

Page 179: ...o use less EGR and higher oxygen levels for better combustion while meeting the EPA near zero NOx emissions requirement of NOx By using DEF we avoid the disadvantages of increasing EGR to massive leve...

Page 180: ...DEF solution Only use approved DEF fluid Use only Diesel Exhaust Fluid that is clearly labeled as meeting ISO 22241 standards and certified by the American Petroleum Institute The container must displ...

Page 181: ...m3 Refracting Index at 20 C 68 F 1 3814 1 3843 Alkalinity as NH3 0 2 Biuret 0 3 Aldehyde 5 mg kg Insolubles 20 mg kg Phosphate PO4 0 5 mg kg Calcium 0 5 mg kg Iron 0 5 mg kg Copper 0 2 mg kg Zinc 0 2...

Page 182: ...id DEF If urea solution comes into contact with the skin rinse with plenty of water and remove contaminated clothing If urea solution comes into contact with the eyes rinse for several minutes and cal...

Page 183: ...DEF in the tank A DEF low level warning will activate when DEF is low If a driver runs out of DEF completely vehicle power will be reduced When the DEF tank is refilled the engine will resume normal p...

Page 184: ...ation may be visible during a cold start If black exhaust smoke is visible during engine operation this indicates a problem with the exhaust aftertreatment system Take the vehicle to an authorized Mac...

Page 185: ...F Dosing Unit Aftertreatment DEF Pump Aftertreatment DEF Return Valve The ACM UDS also monitors the following values in the exhaust aftertreatment system Aftertreatment DEF Dosing Pressure Aftertreatm...

Page 186: ...m s operation Also the Electronic Malfunction Indicator lamp illuminates up in the Instrument Cluster for both these fault messages The driver should acknowledge this message by pressing the Enter but...

Page 187: ...Mack Emissions Solution 179 W3036326 Electronic Malfunction Indicator W3060871 Urea System Low Voltage W3060872 Urea System Fault Check CHARGER BATTERY Screen...

Page 188: ...on switch where the middle position is neutral C0029148 DPF Smart Switch 1 Upper Position Regeneration Position 3 Down Position Inhibit Position if equipped 2 Middle Position Neutral Position CAUTION...

Page 189: ...e aftertreatment system is hot enough to remove soot without injecting additional fuel into the DPF system Active regeneration require additional fuel injection into the DPF Parked Regeneration The Af...

Page 190: ...the engine speed may ramp as high as 1 100 rpm 5 Parked regeneration can take between 45 and 90 minutes to complete 6 After regeneration has completed and the exhaust temperature has returned to norma...

Page 191: ...later time when the vehicle is in a safe location However if a parked regeneration is stopped too many times the vehicle must be taken to a MACK service facility The service facility will use a servi...

Page 192: ...184 Mack Emissions Solution W8056653...

Page 193: ...n required on passenger cars for many years On Board Diagnostics OBD is a system that monitors the functions of emissions related components and alerts the vehicle operator to any detected need for an...

Page 194: ...eatment icons are located in the instrument cluster per the following images Example Instrument Cluster W3061563 1 Malfunction Indicator Lamp MIL 2 CHECK Lamp 3 Aftertreatment DEF Low Lamp 4 High Exha...

Page 195: ...eneration Required icon flashes when the Diesel Particulate Filter is full overfull and regeneration is needed W3007445 Aftertreatment DPF Regeneration Required Icon NOT IN AUS The High Exhaust System...

Page 196: ...level is low It also Flashes when the level becomes critically low W2029416 Aftertreatment DEF Tank Low Level Indicator DEF Malfunction Indicator Lamp MIL MIL indicates government Regulation On Board...

Page 197: ...e 25 Torque Reduction 0 Aftertreament DEF Tank Gauge Insufficient DEF Pump Pressure Diesel Fuel Refueling 15 W2029415 None 8km h 5mph Road Speed Limit RSL Note Vehicle has to be stationary before 8 km...

Page 198: ...be damaged Exhaust system corrosion may occur between turbocharger and Aftertreatment DPF On Board Diagnostic OBD Diagnostic Trouble Codes DTC Costly repairs Results of misfilling Diesel in Aftertrea...

Page 199: ...or Triggers Aftertreatment DEF Tank Low Level Indicator Warning Lamp Inducement No Tampering None None None Tampering DTC Pending None W3031623 None Tampering DTC Confirmed None W3031623 None Tamperin...

Page 200: ...000 mi whichever comes first Or replace the air cleaner when either the air cleaner gauge on the air cleaner locks in the red or when the dash mounted gauge shows an air inlet restriction of 5 kPa in...

Page 201: ...nce and lubrication procedures refer to the Maintenance and Lubrication Manual TURBOCHARGER The engine turbocharger operates at very high speed temperatures and pressure Turbo bearing lubrication is c...

Page 202: ...atch the finish Do not park near factories with heavy smoke fallout for extended periods of time Bird droppings have high acid content and can damage freshly painted surfaces They should be cleaned of...

Page 203: ...irect water spray into the door lock cylinders as the water may freeze in the lock mechanisms CAUTION To ensure durability proper care of the paint finish is important Chemicals used to wash the vehic...

Page 204: ...atching body paint with grit from other areas Rinse truck thoroughly with water and wipe dry with a soft clean chamois or all cotton towels to avoid surface scratches and water spotting CAUTION Do not...

Page 205: ...ith a hard wax at least twice a year Your truck may have a basecoat plus clearcoat Use a basecoat clearcoat wax on your paint finish Polishing Polish your truck only if the paint has lost its shine an...

Page 206: ...ling type towing arrangement Note Tow pins hooks eyes etc are NOT intended for use as long term towing devices CAUTION Failure to disconnect the driveline or lift the drive wheels off the ground befor...

Page 207: ...MAINTENANCE AND LUBRICATION 199 C0032899 C0032900 1 Towhook Access...

Page 208: ...e the engine is COLD prior to starting at the beginning of the work day or after the vehicle has sat approximately 2 hours At normal operating temperature engine oil temperature above 79 4 C 175 F oil...

Page 209: ...t DO NOT fill to more than 95 of liquid capacity COOLING SYSTEM The cooling system is a pressurized system The coolant is circulated by a centrifugal pump It is a typical system in most respects but t...

Page 210: ...should be checked by observing the coolant in the expansion tank C0032903 Draining the Cooling System Whenever repairs are to be made which would require disconnection of coolant hoses etc the coolin...

Page 211: ...K cooling system Cooling System Maintenance The cooling system must be maintained by performing regularly scheduled maintenance as outlined in the Maintenance and Lubrication Manual Cold weather opera...

Page 212: ...Routing The following diagram shows the accessory drive belt and main belt routing with and without air conditioning This diagram is located in a clear area on the outside of the left frame between th...

Page 213: ...ust 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 C0032...

Page 214: ...curate tyre pressure gauge NEVER bleed air from a hot tyre as it will then be underinflated Refer to the specific tyre manufacturer s data books or to the vehicle certification label for a complete li...

Page 215: ...chanic Refer to the Maintenance and Lubrication Manual for more information Tyre Manufacturer s Data Book Specific and more detailed information can be obtained by referring to the technical data book...

Page 216: ...on a regular basis Axle end seals Engine seals Transmission seals Drive axle seals Oil filters Oil and hydraulic lines if equipped Refer to the Maintenance and Lubrication Manual specific tyre manufac...

Page 217: ...C vehicle always turn the ignition switch OFF before connecting the batteries 1 Connect positive cable to positive post of discharged battery 2 Connect the other end of the same cable to the positive...

Page 218: ...210 MAINTENANCE AND LUBRICATION ELECTRICAL Circuit Breaker and Relay Panels C0032908...

Page 219: ...ept 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 ro...

Page 220: ...repaired SAE Type II automatic reset non cycling circuit breakers if equipped provide a complete circuit disconnect until the overload is corrected The power to the affected circuit breaker must be sh...

Page 221: ...2 20 amp Fuse F80 Battery power to TECU 3 30 amp Fuse F81A Battery power to relay 73 4 10 amp Fuse F79 Battery power to gear Selector and GECU 5 Relay 93 Engine Retarder LATCH 6 Relay 72 GSECU Ignitio...

Page 222: ...rosion 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 assembli...

Page 223: ...h Switch Engine Brake Cruise On Off Set Resume Override Switch Park Brake PTO w o T2000 Spare VCU Relay Coils Power Spare ABC Cluster 20 10A 21 20A 22 20A 23 20A Moto Mirrors Windshield Wiper Washer L...

Page 224: ...d Trailer Stop Lps Reverse Neutral Power Cab Trailer Clearance Lps 36 15A 37 30A 38 25A 39 30A Horn Trailer Tail Lps Engine Control Unit ign Trailer ABS Power 40 15A 41 15A 42 20A Spare Engine Compart...

Page 225: ...jacks on the dashboard or battery post 12 volts ignition ground post buffered tachometer RPM output and buffered speedometer MPH output connections available on the electrical equipment panel Each co...

Page 226: ...stor Logic TTL compatible square wave signals that are calibrated to provide a standard pulse rate of 12 pulses per engine revolution for the tachometer output and 18 645 pulses per kilometer for the...

Page 227: ...e chassis wire harnesses This harness provides connections to the V MAC IV system when signals for PTO inputs Set Decel inputs engine speed vehicle speed etc are required The harness also provides spa...

Page 228: ...provide connections to the following circuits Upper Connector Electrical Connection Fused amps 12V battery feed 30A 12V battery feed 30A 12V Ignition feed 30A 12V Ignition feed 30A Reverse Power feed...

Page 229: ...H Turn Stop Lamp Signals Buffered MPH RPM Output Signals Dash Mounted Body Lamp Signal Spare 14 Gauge 5 Spare 16 Gauge 1 An input signal 12V connection is included in Body Link if the Body Lamp is ord...

Page 230: ...n s may occur with certain metric thread inch thread fastener combinations and with fastener combinations involving incompatible metric fastener systems A given thread mismatch condition can result in...

Page 231: ...s 1 pound square inch 1 8 x degrees Celsius 32 degrees Fahrenheit 83267 Imperial gallon 1 gallon U S liquid U S to SI Conversions 03937 inch 1 millimeter 6214 mile 1 kilometer 2 1134 pints U S liquid...

Page 232: ......

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