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Mack Granite GU Series, Operator'S Handbook Manual

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Mack Granite GU Series Operator'S Handbook Manual Download 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. This would cause all current to flow through the master ground circuit
breaker resulting in overload.

Summary of Contents for Granite GU Series

Page 1: ...Mack GU Series 21394647 21394647 21394647 April 2010 Mack Trucks Inc 2010 Printed in U S A Mack GraniteTM Series GU Series Mack GraniteTM Series GU Series ...

Page 2: ......

Page 3: ...A and Mack Trucks Inc should be informed immediately if you believe that the vehicle has a defect that could cause a crash injury or death Contact NHTSA by calling the Auto Safety Hotline at 1 888 327 4236 by writing to NHTSA U S Department of Transportation Washington DC 20590 by TTY at 1 800 424 9153 or visit their website at www nhtsa dot gov MackTrucks Inc Greensboro NC USA Order number PV776 ...

Page 4: ...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 Call 1 800 866 1177 for MACK OneCall 23 Questions and Complaints 23 Addresses 24 Additional Assistance 25 REPORTING SAFETY DEFECTS 26 United ...

Page 5: ...IMATE CONTROL 87 SLEEPER CLIMATE CONTROL 89 LIGHT CONTROL PANEL 90 LOWER CONSOLE PANEL 91 STEERING COLUMN 92 Combination Starter and Electrical Switch 92 Steering Wheel Adjustment 92 Turn Signal Lever 93 Stalk Switch If Equipped Co Pilot Only 94 FLOOR PEDALS 95 MISCELLANEOUS CONTROLS 96 Dome Light 96 Interior Cab Lights Sleeper Cab 97 Air Horn 97 Fresh Air Vent 98 Cab Air Filter 99 Microphone 99 A...

Page 6: ...IRE PRESSURE CONTROL SYSTEM IF EQUIPPED 141 Operating the Dana Tire Pressure Control System 141 Tire Changing Procedure 147 CRUISE CONTROL OPERATION 149 Speed Control Switches 149 Setting Cruise Control 149 Disengaging Cruise Control 150 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 15...

Page 7: ...FTING INSTRUCTIONS 193 Shifting Instructions for Allison Automatic Transmissions 193 MACK T306G Shifting Instructions 194 MACK TM308 Shifting Instructions 195 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 ...

Page 8: ...ducement 261 Aftertreatment DEF Quality Driver Warning Inducement 262 Misfilling Diesel or Aftertreatment DEF Tanks 263 SCR Tampering Driver Warning Inducement 264 Warranty and Maintenance 265 Exhaust Aftertreatment System Maintenance 265 Engine Maintenance Intervals 265 MAINTENANCE AND LUBRICATION 266 MAINTENANCE INTRODUCTION 266 TURBOCHARGER 267 CLEANING YOUR VEHICLE 268 Exterior Washing 268 Cab...

Page 9: ...LIGHTS 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: ...an unsafe practice that could result in serious personal injury or death A danger advisory banner is in white type on a black background with a black border WARNING Warning indicates an unsafe practice that could result in personal injury A warning advisory banner is in black type on a gray background with a black border CAUTION Caution indicates an unsafe practice that could result in damage to t...

Page 11: ......

Page 12: ...ons may differ from one model to another While every effort has been made to cover all current arrangements do not hesitate to consult your MACK distributor if a question arises Honest personal service is standard with every MACK sale CAUTION Mack Trucks Inc would like to point out the important role that the driver plays in the life of the vehicle Only trained and informed drivers should operate ...

Page 13: ...e daily operation of this vehicle Please read it thoroughly pay particular attention to advisory labels that have been included to draw attention to important issues of operator safety and overall performance Information and illustrations in this handbook are based on the latest production usage at the time of printing and are subject to change without prior notice Note Basic maintenance and lubri...

Page 14: ... maintenance schedules overspeed logs fault tables trip summaries For a complete description of the V MAC IV system refer to the applicable V MAC Operator s Guide which is supplied with the vehicle Additional information concerning service diagnostics programming and vendor equipment interface application is available from the Mack Trucks Inc Service Publications Department Contact your local MACK...

Page 15: ...ations 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 C0029554 The VIN label is located on the inside door frame below the driver seat C0028941 ...

Page 16: ...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: ... information engine model serial number etc advertised horsepower at rated speed emissions regulations to which the engine conforms and inlet and exhaust valve lash settings Examples of the 49 state EPA approved and 50 state EPA and California approved engine identification labels are given below W2040455 Engine Identification Label 49 State EPA Approved Engine without California Clean Idle W20404...

Page 18: ... 700 rpm At speeds above low idle and without a PTO engaged idle time will be limited to five minutes after which the engine will revert back to low idle Vehicles equipped with a Clean Idle engine are identified by a label which is affixed to the left front corner of the hood on conventional models GU W2056289 Clean Idle Engine Label Transmission Identification The MACK T300 Series transmission se...

Page 19: ...te is located on the rear right side of the main case near the lower end 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: ...e 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: ...t system Diesel Particulate Filter Use of Ultra Low Sulfur Diesel ULSD fuel and EO O Premium Plus or VDS 4 specification high performance diesel engine oil is required in this vehicle Note Use of improper or unapproved fuel or engine oil will void the engine and aftertreatment system Diesel Particulate Filter warranty 2010 emission engines REQUIRE the use of EO O Premium Plus or VDS 4 specificatio...

Page 22: ...equired by Federal Motor Vehicle Safety Standards Mack Trucks Inc makes no representation as to conformity with the Standards For complete warranty information refer to the Pedigreed Protection Plan provided with each vehicle ENGINE GASEOUS EMISSION CONTROL SYSTEMS WARRANTY MAINTENANCE Note For emission control systems information on engines other than MACK refer to the engine vendor s publication...

Page 23: ...per or inadequate maintenance and use of improper diesel fuel or DEF Damage resulting from accident acts of nature or other events beyond the control of Mack Trucks Inc Inconvenience loss of use of the vehicle commercial loss of any kind including but not limited to consequential or incidental damages Any vehicle in which the odometer has been altered or damaged so that mileage cannot be readily d...

Page 24: ...PF Assembly with Aftertreatment Diesel Oxidation Catalyst DOC Aftertreatment Doser Diffuser Pipe Aftertreatment Fuel Doser Mounting Fuel lines to Aftertreatment Fuel Doser Aftertreatment Fuel Shutoff Valve Aftertreatment Fuel Pressure Sensor Discharge Recirculation Valve DRV Heat Mode Discharge Recirculation Valve DRV Solenoid Engine Turbocharger Compressor Bypass Actuator Heat Mode Engine Turboch...

Page 25: ...Catalytic Reduction SCR Catalyst Aftertreatment Diesel Exhaust Fluid DEF Pump Aftertreatment DEF Dosing Absolute Pressure Sensor Aftertreatment DEF Return Valve Aftertreatment DEF Dosing Valve Aftertreatment DEF Tank Aftertreatment DEF Tank Heater Sender Aftertreatment DEF Tank Heater Aftertreatment DEF Tank Heater Valve Aftertreatment DEF Tank Temperature Sensor Aftertreatment DEF Level Sensor Af...

Page 26: ...ystems is not covered by the emission warranty With the Thermal regenerator DPF system cleaning the ignition electrodes and fuel injection nozzle at the regular maintenance intervals is considered normal maintenance and not covered by the emission warranty Note In response to customer requests Mack Trucks Inc may build vehicles with engines supplied by other manufacturers In these cases each engin...

Page 27: ...ngines following its sale and delivery to the ultimate purchaser or 4 Any person who operates a fleet of motor vehicles following its sale and delivery to the ultimate purchaser Note For specifics of the prohibited vehicle engine modifications refer to the Mack Trucks Inc Body Builders documentation EMISSION CONTROL SYSTEMS WARRANTY CALIFORNIA The California Air Resources Board and Mack Trucks Inc...

Page 28: ... emissions regulations applicable at the time of manufacture of the engine and to be free from defects in material and workmanship under normal use and service up to 60 months or 100 000 miles or 3 000 engine operating hours whichever occurs first provided that all Mack Trucks Inc maintenance requirements are followed as described in this manual All warranty periods are calculated from the date in...

Page 29: ...et Manifold 11 Crankcase Breather 12 Crankcase Separator 13 Crankcase Tubing and Hoses before Separator 14 Aftertreatment Wiring Harness 15 After treatment Control Module ACM 16 Aftertreatment Diesel Particulate Filter DPF Assembly A Aftertreatment DPF Assembly with Aftertreatment Diesel Oxidation Catalyst DOC Aftertreatment Doser Diffuser Pipe Aftertreatment Fuel Doser Mounting Fuel lines to Afte...

Page 30: ...GR Differential Pressure Ambient Air Temperature AAT 18 SCR Aftertreatment Selective Catalytic Reduction SCR Catalyst Aftertreatment Diesel Exhaust Fluid DEF Pump Aftertreatment DEF Dosing Absolute Pressure Sensor Aftertreatment DEF Return Valve Aftertreatment DEF Dosing Valve Aftertreatment DEF Tank Aftertreatment DEF Tank Heater Sender Aftertreatment DEF Tank Heater Aftertreatment DEF Tank Heate...

Page 31: ...e 2 In an Emergency In an emergency where an authorized MACK facility is not available repairs may be performed at any available service establishment or by the owner using any replacement part within the limitations of paragraphs 3 and 4 in this section An emergency condition exists under this section if after 30 days repairs have not been completed or parts are not yet available MACK will reimbu...

Page 32: ...the Emission Control Systems Warranty Malfunctions caused by misuse improper adjustments modification alteration tampering disconnection improper or inadequate maintenance and use of improper diesel fuel Damage resulting from accident acts of nature or other events beyond the control of Mack Trucks Inc Inconvenience loss of use of the vehicle commercial loss of any kind including but not limited t...

Page 33: ...ulti binder set contains service information covering all MACK components i e engines transmissions front and rear axles cabs fuel systems electrical systems Note If your vehicle contains a number of non MACK vendor components the Class 8 Custom Collated Service Manual might be more appropriate Class 8 Custom Collated Service Manual Class 8 Custom Collated Service Manual on CD This tailor made set...

Page 34: ...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 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 res...

Page 35: ...oodridge IL 60517 TEL 630 910 3330 FAX 630 910 3331 Southwestern and Western Regions 5605 N MacArthur Blvd 550 Mail P O Box 165408 Irving TX 75016 5408 TEL 972 518 1614 FAX 972 550 0389 Canada Executive Office Mack Canada Inc 5600A Cancross Court Mississauga ON L5R 3E9 TEL 905 366 3400 FAX 905 366 0165 Australia Mack Trucks Australia Pty Ltd CNR Archerfield and Boundary Roads Mail P O Box 364 Rich...

Page 36: ...de the following information Vehicle Identification Number VIN This 17 digit number is typically located on a label on the driver side door latch post and behind the front axle on the right front frame rail Model and year of the vehicle Date that the vehicle was purchased and put into service Date s and mileage of repair s Dealer that sold and or serviced the vehicle Description of unresolved serv...

Page 37: ...ion 400 Seventh Street S W Washington DC 20590 You can also obtain other information about motor vehicle safety from the Vehicle Safety Hotline Canada Canadian customers who wish to report a safety related defect to Transport Canada Defect Investigations and Recalls may telephone the toll free hotline at 1 800 333 0510 or contact Transport Canada by mail at Transport Canada ASFAD Place de Ville To...

Page 38: ...ts The EDR on your MACK vehicle records vehicle speed engine rpm time and date plus a variety of pedal and switch positions both before and after an event Sudden vehicle deceleration or the occurrence of certain other vehicle operational characteristics will define trigger an event Optional equipment available for your MACK vehicle such as the Eaton VORAD Collision Warning System may also provide ...

Page 39: ...st fumes could leak into the cab area and death can result On a regular basis inspect the exhaust system for leaks and repair any leakage DANGER Driver attitude is the most important part of any effective vehicle safety system Mack Trucks Inc strongly encourages all drivers and passengers to use their seat belts drive defensively remain alert and respect the speed limits Many accidents can also be...

Page 40: ...und and use brushes and squeegees mounted on extension poles When better access is necessary for instance when washing the cab roof use sturdy ladders held in place by someone on the ground WARNING Secure loose objects Loose objects in the cab or sleeper can be dangerous in a sudden stop or on bad roads Secure any appliance added to the vehicle such as a refrigerator or a radio WARNING Keep clear ...

Page 41: ...the driver side door 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 Both labels are described below Incomplete Vehicles C0028955 A chassis cab is an incomplete vehicle with a completed occupant compartment that requires the additi...

Page 42: ...d by the body manufacturer is affixed in the same general location This label provides information pertaining to Gross Vehicle Weight Rating GVWR Gross Axle Weight Rating GAWR tire and rim information etc On MACK completed vehicles this label contains the date of manufacture VIN GVWR GAWR and tire and rim data It is found in one of the NHTSA locations listed above C0028956 ...

Page 43: ... situations which can cause personal injury or equipment damage 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...

Page 44: ...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 1 Right Side Frame Rail 2 Hood Prop ...

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: ...ON 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: ...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: ...plied from the factory reflective devices will be applied on the rear lower portion of the cab Refer to the illustration Locations of these reflective devices may vary from this illustration depending on the cab model and or equipment added to the rear of the cab C0029023 1 White Reflective Devices Back of Cab 2 Red and White Reflective Devices when not equipped with mudflaps and brackets 3 Red an...

Page 55: ...e in FIRM contact with the vehicle or ground WARNING When entering or exiting the cab be aware of the condition of the steps and handrails Clean any fuel oil or grease off of the steps before entering the cab During cold weather operation ice and snow may accumulate and should be cleaned off to prevent slipping During cold wet conditions when ice slush or snow may accumulate on the cab doorstep an...

Page 56: ...and 2 feet in FIRM contact with steps and handholds at ALL times Be sure of where you step and grab the handholds Keep the areas clean Be EXTRA careful in rainy snowy etc weather Do NOT jump from vehicle Note The illustrations on the following pages are typical for purposes of emphasizing a safe method for hand foot placement and movement during cab entry exit Your vehicle may not look exactly lik...

Page 57: ...oot to the cab floor See figure 3 4 Move one hand at a time to the steering wheel inside handhold if equipped or cab interior Bring the other foot inside the cab and sit down See figure 4 Exit To exit follow the illustrations in reverse order 1 With both hands gripping the steering wheel inside handhold if equipped or cab interior stand up and face the inside of the cab Move one foot to the top st...

Page 58: ...SAFETY INFORMATION 47 C0029833 ...

Page 59: ...on 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 order 1 With the left hand gripping the interior and the right hand gripping the inside handhold stand up and face the inside of the cab Move your right foot to the top step Move your left foot to the to...

Page 60: ...SAFETY INFORMATION 49 C0029834 ...

Page 61: ... with one foot planted firmly on the middle step move the other foot to the top step See figure 3 4 Finally move your other foot from the middle step onto the deck plate and grab the next available handhold See figure 4 Climbing Down To climb down from behind the cab follow the illustrations in reverse order 1 Grab the available handholds with both hands and move one foot to the top step See figur...

Page 62: ...SAFETY INFORMATION 51 C0029835 ...

Page 63: ...vel of blades Install new refills for any blades that are cracked brittle torn or coated with road oil along the wiping edge Windshield Washers Check operation of windshield washer Inspect system hoses and replace if brittle or worn Inspect washer reservoir Drain and flush if dirt particles are evident in washer solution Fill reservoir with commercially available non freezing type washer fluid CAU...

Page 64: ...nder these conditions it may be necessary to drill holes to penetrate the hollow core This allows entrapped air to escape thereby easing the opening closing of cab door s Be sure to keep the key locks clean and dry to prevent occasional winter freeze up Use of antifreeze lubricants is neither required nor recommended Outside Mirror Heater In areas of frequent snowfall and ice it may be beneficial ...

Page 65: ... 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 Inside the extended rider seat Fire Extinguisher Optional Your vehicle may be equipped with a fire extinguisher which is located inside your cab Check your fire extinguisher regularly to make sure it is fully charged ...

Page 66: ...UMENTS AND CONTROLS 55 CAB INTERIOR C0029134 1 Instrument Panels 5 Hazard Switch 2 Cab Climate Control Panel 3 Foot Pedals 4 Tilt Control Pedal 6 Turn Signal Flash HI LO Beam Courtesy Flash and Flash to Pass ...

Page 67: ...trations on the following pages Colors To promote visual recognition internationally specific colors for tell tales have been established Unless governmental regulations in the area where the vehicle is to be used or engineering directives specify otherwise the standard colors are Blue high beam headlights engine maintenance Flashing Green turn signals Flashing Red hazard condition involving the s...

Page 68: ...easy reach The instrument panel as shown in the following drawing is broken down into several main sections For easy identification we refer to them from left to right as Panels A B C D E and F where necessary Note This section shows the instruments and controls available for this vehicle at the time of publication However depending on options your vehicle may not have all the instruments and cont...

Page 69: ... 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: ...l 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 Tachometer 15 DOT Matrix Display 7 Speedometer 16 Left Hand Tell Tale 8 Primary Air Pressure 17 DEF Level 9 Secondary Air Pressure ...

Page 71: ...MENTS AND CONTROLS Panel A C0029136 1 Manifold Pressure Gauge If Equipped 4 Exhaust Pyrometer If Equipped 2 Engine Oil Pressure Gauge 3 Engine Coolant Temperature 5 Transmission Oil Temperature Gauge If Equipped ...

Page 72: ...INSTRUMENTS AND CONTROLS 61 Panel B W3056238 ...

Page 73: ...reen 11 On Board Diagnostics Indicator 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 ATC Indicator Amber 14 Left Turn Signal Indicator Green 29 Neutral Indicator Amber 15 Engine Shutdown Indicator Red 30 Fasten Seat Belt Warning Indicator Red 16 Aftertreatment DEF Low Le...

Page 74: ...S 63 Panel C C0029138 36 Air Application or Air Suspension Gauge If Equipped 39 Air Suspension Pressure 37 Hand Control Brake Lever 40 Secondary Air Pressure Gauge 38 Engine Oil Temperature Gauge 41 Primary Air Pressure Gauge ...

Page 75: ...witch If Equipped 59 Parking Brake Valve 44 Optional Switch 60 Optional Switch 45 Optional Switch 61 Trailer Air Supply Valve 46 Optional Switch 62 Optional Switch 47 Optional Switch 63 Optional Switch 48 Optional Switch 64 Optional Switch 49 Storage Box or Automatic Transmission Selector If Equipped 65 Optional Switch ...

Page 76: ... listed in alphabetical order 1 Manifold Pressure Gauge If Equipped Measures the charge air boost pressure in the intake manifold 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 3 Engine ...

Page 77: ...aves fuel by reducing the amount of time spent idling to keep the vehicle s batteries charged the engine warm or the cab and sleeper comfortable Once the optional Integrated Temp A Start feature is activated via a dash switch the system will automatically start and stop the truck engine Safety overrides prevent the system from activation if the transmission is in gear the hood is up or the parking...

Page 78: ...th 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 13 Parking Brake Indicator Red Indicates that the parking brake is engaged 14 Left Turn Signal Indicator Green Flashes green when the left turn signal is ...

Page 79: ...es when the level becomes critically low 17 Anti Lock Brake System ABS Indicator Amber Indicates an ABS malfunction If the light turns on and stays on a malfunction is indicated For additional information on operating an ABS equipped vehicle refer to Anti Lock Brake System ABS page 161of the Operationsection Note When an ABS malfunction is detected anti lock braking in the affected wheel s will be...

Page 80: ... of information supplied by the V MAC IV electronic control system The operator presses a push button located directly below the driver information display to retrieve information Note The Basic Display does not use a stalk switch which is only available with the Co Pilot display The following information is available in the Basic Display Current Conditions C0029140 Trip Information ...

Page 81: ...70 INSTRUMENTS AND CONTROLS C0029141 ...

Page 82: ...INSTRUMENTS AND CONTROLS 71 Diagnostics W3036575 W3036576 W3036583 ...

Page 83: ...ith messages on the display screen For more information on how to use the Co Pilot please consult the V MAC IV Vehicle Management and Control with Co Pilot Display Operator s Guide TS898 GuardDog Optional Must be Enabled GuardDog an active maintenance monitoring system uses sensor readings to show the status of routine maintenance requirements If the vehicle is equipped with the GuardDog system Co...

Page 84: ...INSTRUMENTS AND CONTROLS 73 C0029144 ...

Page 85: ...em ABS page 161of the Operationsection Note When an ABS malfunction is detected anti lock braking in the affected wheel s will be disabled and normal braking will return the other wheels will retain anti lock braking Operate the vehicle normally and have the ABS system serviced to correct the fault 23 Cruise Control Indicator Green Indicates that cruise control is engaged 24 Power Take Off Operati...

Page 86: ...ambers in the tractor and trailer if equipped OR Air Suspension Gauge If Equipped Indicates the air pressure being delivered to the air suspension system 689 kPa 100 psi range 37 Hand Control Brake Lever Pull down to activate the trailer brakes or the rear axle brakes in the case of a platform truck WARNING The hand control brake system must NOT be used for parking Do NOT use to apply service brak...

Page 87: ... brakes and is indicated by the green pointer on the gauge Secondary air pressure is supplied to the steering axle brakes and indicated by the orange pointer 42 Wiper Speed Delay Wash Master Switch Depress top of the rocker switch to activate windshield washer Toggle switch in top position turns wipers on HIGH Toggle switch in second position from top turns wipers on LOW Toggle switch in the cente...

Page 88: ...ission Operator s Manual supplied with this vehicle 50 Air Filter Restriction Indicator If Equipped Indicates that the element needs servicing or replacement When the red flag locks into position service as soon as possible to prevent engine damage then reset the indicator after the filter change Check the air filter restriction indicator daily 51 Accessory Power Outlet See instructions under Acce...

Page 89: ... USB port please refer to the radio manual that is supplied with your vehicle 54 Cab Climate Control See instructions under Cab Climate Control listed in the Instrument and Controls Section of this manual 55 Optional Switch 56 Optional Switch 57 Optional Switch 58 Optional Switch 59 Parking Brake Valve Yellow diamond shaped knob Pull to apply Push to release Applies tractor parking brakes and trai...

Page 90: ... 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: ...r Switch 10 5th Wheel Slide Switch 3 Air Suspension Control Switch 11 Inside Outside Air Switch 4 Automatic Traction Control Switch 12 Load Light Switch 5 Body Warning Lamp 13 Mirror Defrost Switch 6 Daytime Running Lights Override Switch 14 Motorized Mirror Joy Stick 7 Engine Brake Switch 15 Power Divider Lockout Switch 8 Shutdown Override Switch 16 Power Take Off Control Switch ...

Page 92: ...p Down Switch 7 Spin Light Switch 2 Push Axle Up Down Switches 8 Strobe Switch 3 QUAL COMM Panic Button 9 Telma Retarder Lamp 4 Right Hand Only Door Lock Switch 10 Vent Fan Switch 5 Right Hand Only Window Lift Switch 11 Windshield Defrost Switch 6 Snow Plow Lamps Switch ...

Page 93: ...derside of the trailer Failure to do so will result in the trailer being improperly connected After the trailer has been coupled and the trailer landing gear has been raised make sure that the 5th wheel jaws have properly engaged the trailer king pin and there is no gap between the 5th wheel plate and the bottom of the trailer CAUTION DUMP BODY Always exhaust the air from the bags before raising t...

Page 94: ...d put on chains Body Warning Lamp The Body Lamp illuminates a RED warning icon on the D panel to alert the driver of a body function as defined by the bodybuilder As an example the body warning lamp will illuminate to alert the driver that the dump body is not fully down C0029214 Daytime Running Lights DRL Override Switch Daytime Running Lights DRL come standard on all MACK vehicles and can be opt...

Page 95: ...nformation Fan Control Manual Override Switch Allows the operator to manually control the engine cooling fan 5th Wheel Slide Switch Locks and releases a sliding 5th wheel using air pressure this allows the 5th wheel to be properly positioned The indicator lamp will illuminate when the 5th wheel is unlocked Prior to model year 2001 it was necessary to use the trailer Hand Brake Control Lever to act...

Page 96: ...uxiliary axle s will automatically raise when the transmission is shifted into reverse C0029216 1 Air Pressure Gauge 2 Air Pressure Regulator QUAL COMM Panic Button If your vehicle is equipped with this option refer to the QUAL COMM literature provided with the vehicle Right Hand Only Door Lock Push the top in to lock the right hand door Right Hand Only Window Lift Press the top of the switch to r...

Page 97: ...to turn light off Telma Rear Axle Mounted Retarder Indicator Lamp If Equipped The Telma does not have a disable switch It is always on and will operate at different levels depending on application of service brake The indicator will show you the level you are retarding the vehicle 20 40 60 80 or 100 Note The Telma retarder is disabled if there is an ABS event C0029217 Vent Fan Switch Press switch ...

Page 98: ...ure Control Knob 5 A C ON OFF Button 3 Mode Knob 1 Blower Control Knob This knob controls fan speed from OFF to 4 highest speed 2 Temperature Control Knob Controls the temperature of the air in the cab from COOL far left to HOT far right 3 Mode Selection Knob Controls the direction of air flow around the cab as follows ...

Page 99: ...ow through the floor vents only Note The Mode Selection knob can be rotated to any position see above This allows the operator to select the desired amount of blend between the positions 4 Fresh Recirculation Switch or Button Selects the cab intake air between fresh air from outside the cab and recirculated air inside the cab Note For maximum air conditioner performance select recirculated air 5 A...

Page 100: ... warm air flows out the sleeper box air vents As a result the sleeper may become quite warm and uncomfortable on hot summer days To use the sleeper box air conditioner make sure that the Cab air conditioning unit is activated and the cab fan control switch must be ON any speed Then on the sleeper climate control panel move the mode selection knob to the A C position and turn the temperature contro...

Page 101: ...he left position all lights are off With the knob in the middle position the parking lights and interior panel lights will illuminate With the knob in the far right position the headlights will turn on To turn on the fog lights if equipped put the knob in the far right position and pull out the fog light button see Figure above The fog light symbol will illuminate indicating the lights are on To a...

Page 102: ...RUMENTS 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: ...r sounds if air system pressure is below 448 34 kPa 65 5 psi or if there is low oil pressure The buzzer shuts off as soon as sufficient air oil pressure is restored Steering Wheel Adjustment WARNING Adjust the steering wheel position BEFORE attempting to move the vehicle to avoid losing control of the vehicle Adjusting Tilt and Telescope Push down on the foot pedal located at the left kick panel t...

Page 104: ...he turn signal lever is located on the steering column It performs a number of functions including activating the high and low beams signal switch and the hazard switch The signal switch can be used for courtesy flashing of marker lights and for the flashing of high beams C0029224 1 Turn Signal Lever 3 Pull for Hazard Red 2 Stalk Switch C0029225 ...

Page 105: ... stalk switch is used to access navigate view and change information available in the driver information display Co Pilot display The following illustration shows the stalk switch C0029226 1 ESC Escape 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 fu...

Page 106: ... menu For more information on Co Pilot display please refer to the V MAC IV Operator s Guide FLOOR PEDALS C0029227 1 Accelerator Pedal Depress to increase engine vehicle speed release to decrease engine vehicle speed 2 Brake Treadle Valve Depress to activate the service brakes 3 Clutch Pedal Depress to disengage the clutch The clutch pedal is only found on trucks equipped with manual transmissions...

Page 107: ...the bottom position on the driver side and on the passenger side the dome light will come on when the cab door is opened and go off when it is closed Push the switch up to turn the dome light on when the doors are closed for either the driver side or the passenger side Depress the CAB switch above the driver up when doors are closed to turn both dome lights on ...

Page 108: ...river Side 1 Map Light Switch Activates the map lights which are located in the headliner to the left of sun visor 3 Sleeper Light Switch Activates the sleeper ceiling lights 2 Dome Light Switch Activates the dome lights Air Horn C0029232 The air horn s if equipped is activated by pulling down on the cord that is located above the driver near the overhead console ...

Page 109: ...ab interior Move the vent lever to the left or right to open the vent Move the lever to the left to close the vent On chassis equipped with a sleeper cab there is an air vent located on either side of the bunk Pull handle to the left or to the right depending on what side of the cab you are on to open the vent ...

Page 110: ...sure the efficiency of the heating and air conditioning system Failure to replace the filter may cause damage to heater AC components Microphone C0029235 Microphone The microphone is located above the driver in the headliner It is available on the Mid Level radio with Blue Tooth Hands free option This is what is used to talk into when the phone is connected to the truck For more information on the...

Page 111: ... 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 outlets located above the bunk ...

Page 112: ... Cab on Dashboard in Day Cab Red This is a 12 volt switched battery connection It is used to power the vehicle s CB radio It is protected by a 15 amp circuit breaker and supplies power when the key is in the ACCESSORY position or ON position CB Radio Power Jack Located in Headliner on Sleeper Cab on Dashboard in Day Cab Black This is a ground connection It is used as a power return connection for ...

Page 113: ...102 INSTRUMENTS AND CONTROLS C0029240 C0029241 ...

Page 114: ...ip list The report should list all defects or deficiencies discovered by the driver A pre trip inspection prepares for the end of work report Starting on the next page are suggested guidelines to be used in performing truck tractor and trailer pre trip inspections Depending on the application of the vehicle being used these guidelines should be modified to include other necessary inspection points...

Page 115: ...nd hazard lights Apply parking brakes Pull the hood release lever or release the hood latches raise hood Step 1 Left Side of the Cab Left Front Wheel Check condition of wheel rim Especially look for cracks missing lockrings bent or broken studs clamps or lugs Check condition of tire properly inflated no serious cuts bulges tread wear or any signs of misalignment valve stem not touching wheel rim o...

Page 116: ...urrounding areas for coolant oil and fuel leaks Check wiring harnesses for signs of damage Step 2 Front of Cab Area Condition of Windshield Check for damage and clean if dirty Check windshield wiper arms for proper spring tension Check wiper blades for any damage dead rubber and attachment to arm Lights and Reflectors Lower hood and inspect parking clearance and identification lights on hood and c...

Page 117: ... drum With brakes released look for a noticeable gap between lining and drum This check cannot be made if dust covers are in place Condition of brake air hose check for any chafing Check brake chamber mounting bolts and bracket With brakes applied or released look for conspicuously different positions of the slack adjusters Condition of Front Axle and Steering System Right Side No loose worn bent ...

Page 118: ...ng secured against snagging and chafing Step 5 Right Rear Vehicle Area Dual Wheels One or Two Axles Check condition of wheels and rims Especially look for cracks missing lockrings bent or broken spacers studs clamps or lugs Check condition of tires properly inflated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in plac...

Page 119: ...ng Check that air tubing and electrical lines are properly secured to the frame with no damage or chafing Lights and Reflectors Tail lights brake lights and turn signal lights clean and proper color Step 7 Coupling System Area Fifth Wheel Securely mounted to the frame No missing or damaged parts Check that trunnion and plate are properly lubricated Sliding Fifth Wheel Mechanism not worn bent damag...

Page 120: ...and hub no obvious leaking on outside or inside wheel Suspension Check condition of springs leaf or air spring hangers shackles and U bolts no cracks breaks or shifting Brakes Condition of brake drums With brakes released look for a noticeable gap between lining and drum This check cannot be made if dust covers are in place Condition of brake hoses check for any chafing Check brake chamber mountin...

Page 121: ...roperly mounted free from damage and not leaking Trailer cord receptacle properly mounted free of damage plug properly seated and safety catch engaged to prevent accidental disconnect Air and electrical lines properly secured against tangling snagging and chafing with sufficient slack for turns Hooking Up To Trailer Hook Up Preparation Check kingpin and mounting plate on trailer free from wear ben...

Page 122: ... condition adequate for a spare proper size properly inflated Lights and Reflectors Trailer side clearance lights clean operating and proper color Reflectors clean and proper color Frame and Body Frame and crossmembers not bent cracked damaged or missing Proper placarding Body parts not damaged or missing Step 11 Right Rear Trailer Wheel Dual Wheels One or Two Axles Check condition of wheels and r...

Page 123: ...s released look for a noticeable gap between lining and drum This check cannot be made if dust covers are in place Condition of brake hoses check for any chafing Check brake chamber mounting bolts and brackets With brakes applied or released look for conspicuously different positions of the slack adjusters Step 12 Rear of Trailer Area Lights and Reflectors Rear clearance identification and tail li...

Page 124: ...uspension Condition of springs leaf or air spring hangers shackles and U bolts Axle alignment Condition of torque rod arms If equipped with sliding axles check position and alignment Look for damaged worn or missing parts all locks present fully in place and locked Flexible air tubing not cracked cut crimped or otherwise damaged It should be secured against tangling dragging and chafing Brakes Con...

Page 125: ...es cab entry exit hazardous Start the engine If equipped check that exhaust rain cap opens when accelerating engine Check gauges and tell tale light function See the Instruments and Controls section Check headlights tail lights brake lights emergency flashers and turn signal lights for proper operation cleanliness and proper color Check function of low air warning Check clutch function If equipped...

Page 126: ...ak In To ensure many years of reliable trouble free the following break in procedures are recommended Note Oil change filter change and chassis lubrication are no longer required at the 4 828 km 3 000 mile vehicle break in interval Refer to the preventive maintenance schedules outlined in the Maintenance and Lubrication Manual 21394653 for recommended lubrication change intervals for the following...

Page 127: ... On REYCO suspensions also check equalizer nut torque 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 Retorque the spring clip U bolts On REYCO suspensions also retorque ...

Page 128: ...ncerning 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: ...d C0029315 1 With the hood in the locked position pull outward on the plastic handle and disengage the locking tab from the hood latch 2 Swing the rubber strap up and out of the way 3 Repeat this procedure on the other side of the hood Note When the hood is opened the safety latch will drop down into the locked position ...

Page 130: ...s fully open WARNING NEVER take both feet off the ground to tilt the hood Keep at least one foot on the ground to avoid a slip or fall If it is difficult for you to raise the hood get the help of someone who can lift from the rear of the hood WARNING Little effort is required to open or close the hood NEVER take both feet off the ground to tilt the hood Keep at least one foot on the ground to avoi...

Page 131: ... rags and test equipment from the engine compartment before closing the hood WARNING Before closing the hood be sure no one is in the way of the hood s descent Note The safety latch must be released reset before the hood will close See arrow in illustration C0029317 ...

Page 132: ... strap in position and force the locking discs into the hood latch 2 Push inward on the plastic handle to lock the rubber strap in place 3 Repeat this procedure on the other side of the hood C0029318 CAUTION Be sure the hood is latched securely If the latch is not completely engaged the hood could open during operation and cause vehicle damage ...

Page 133: ...vailable 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 See illustration below C0029839 ...

Page 134: ...DERS 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: ... Lock Push backward to lock Push forward to unlock The lock opening appears red when unlocked 2 Door Handle Lift handle to open 3 Door Light The door light automatically comes on when the door is opened and goes out when the door is closed 4 Storage Pouch Large rigid storage pouch 5 Lower View Window Provides safe viewing of low lying obstacles on construction sites 6 Window Crank Turn countercloc...

Page 136: ... Lock Push backward to lock Push forward to unlock The lock opening appears red when unlocked 2 Left Side Power Window Control Push back of button for DOWN front of button for UP 3 Right Side Power Window Control Push back of button for DOWN front of button for UP 4 Power Door Lock Push back of button to lock front of button to unlock The power lock controls both doors Note The right side passenge...

Page 137: ... the doors push the rear of the rocker switch To unlock the doors push the front of the rocker switch To lock with the door open push the lock lever forward and release The lock lever will return to the home position and the door will be locked when closed To unlock pull the paddle and open the door WARNING Always lock the doors while driving This will lessen the chance of personal injury Locking ...

Page 138: ...or Press twice to unlock both doors 5 Press once to lock doors Press twice for horn confirmation 3 Press and hold for 3 seconds to activate panic mode Press and hold for 3 seconds again to cancel panic mode Each transmitter is powered by a 3 volt battery and is water resistant Information concerning battery replacement troubleshooting and programming the transmitters is provided in this section Th...

Page 139: ... UNLOCK button a second time within 3 seconds will unlock both doors Note If AUTO RE ARM feature is selected the keyless entry system will automatically re arm itself 60 seconds after the doors are unlocked with remote transmitter Automatic re arm will cancel if any door is opened before the 60 seconds timer has elapsed Press and hold the AUX button on the transmitter for 0 5 second to turn perime...

Page 140: ...25 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 Remember to check all transmitters ...

Page 141: ... operate at some point where another transmitter does operate replace the battery in the transmitter that does not operate If all transmitters operate approximately five feet from the vehicle the system is operating properly and no repairs should be attempted Programming the Transmitter 1 Turn the ignition switch to the ON position 2 Access the keyless entry module located behind the D Panel 3 Pus...

Page 142: ... 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 operate with ignition on The Remote function cannot operate with ignition on Automatic Re Arm OFF Automatic Re Arm ON External Light turns on for 3 minutes External Light turns on for 5 minutes Three Chi...

Page 143: ...dden stops or impacts This feature allows the operator to move freely under normal conditions Seat belts cannot be locked by jerking on the belt except during sudden stops or harsh bumps Fastening Seat Belt 1 Pull clip so the belt crosses your shoulder and lap and insert it into the buckle until an audible snap is heard DANGER Use the shoulder belt only on the shoulder that is closest to the vehic...

Page 144: ...e sure the clip is securely fastened into the buckle C0029326 3 To tighten the lap portion of the combination belt pull upward on the shoulder portion until the lap portion fits snugly The belt should rest as low on your hips as possible Unfastening Seat Belt Push down on the button to release the belt ...

Page 145: ...nance Keep belt clean and dry Clean with mild soap solution and lukewarm water DANGER Do NOT bleach or dye belt as this may cause severe loss of strength Do NOT install belt in a truck with a weakened floor until the floor has been replaced or reinforced Periodically inspect the following areas and replace any inadequate parts Buckle and Latchplate The buckle and latchplate should mate easily with...

Page 146: ...ent retractor torn webbing etc If there is any question regarding belt or retractor condition replace the appropriate part Komfort Latch System Seat Belt Assembly The Track III three point seat belts installed in this chassis are designed to provide the highest degree of operator safety comfort and convenience Additional comfort is provided by the Komfort Latch mechanism which is incorporated into...

Page 147: ...y release the buckle and give the shoulder belt a quick tug to release the Komfort Latch mechanism Allow the belt to retract into the retractor Emergency Release In the event of an emergency release the seat belt buckle It is not necessary to release the Komfort Latch in an emergency situation Note If forward movement is required while the Komfort Latch mechanism is latched the latch automatically...

Page 148: ... 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: ...ntenance 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 bracket rearward to snap strut in place The strut head should be centered fore aft in the receptacle C0029840 1 Mirror Bracket 3 Plastic Strut Head 2 Receptacle 4 Mirror Breakaway Strut ...

Page 150: ...ing conditions above freezing The restriction of airflow can cause higher exhaust temperatures power loss excessive fan usage and reduced fuel economy CAUTION If a winterfront is used a MACK approved exhaust pyrometer must be installed and closely monitored while the engine is in operation Do NOT exceed the maximum temperature indicated by the red line on the gauge To reduce exhaust temperature do...

Page 151: ...rication CAUTION The maximum allowable engine speed is listed on the warning label on the sun visor DO NOT exceed 2 300 rpm Engine Model Designations The MACK engine model designation system uses letters and numbers to provide a complete unit description MP Engine ID Letters and Number C0029329 MP7 Used as an Example 1 Mack Power 3 Curve Family Econodyne E Maxicruise C Maxidyne M 2 Peak Horsepower...

Page 152: ... get six pressures from which to effectively operate across a wide variety of terrain Highway mode allows for high speed travel on paved surfaces Off Highway permits operation on secondary roads and Emergency provides extremely low tire pressures to help free a stuck vehicle or take on grades that previously were impossible to negotiate without assistance Plus the Dana TPCS has various digital dis...

Page 153: ...ailure to respond may result in tire overheating and reduced tire life or a tire blowout C0029842 Reduce Vehicle Speed This signal reports that the vehicle speed is too fast for the pressure selected You must either reduce speed or select a higher pressure by pressing the appropriate key Continued operation in this mode will result in the system automatically selecting a more appropriate pressure ...

Page 154: ...nner tire rings see Channel Indicators When the system is actively changing tire pressure the indicator arrow above the target mode will flash Service Code Indicator The exclamation point indicates that the value shown in the digital display is not a pressure but rather a service code See Service Codes Section Metric English Indicator This unit of measure indicator tells if the tire pressure is sh...

Page 155: ...es to help free a stuck vehicle CAUTION The EMER feature is for extreme conditions only and should not be used for normal driving C0029845 LOADED INDICATOR The small arrow pointing to the drive wheels indicates whether you have selected loaded or unloaded pressures You must select loaded if your vehicle is carrying any load WARNING Operating a loaded vehicle at unloaded tire pressures may result i...

Page 156: ... This asterisk matches the symbol on the RUN FLAT key and it indicates that the Run Flat feature is selected RUN FLAT KEY This key allows the operator to override the 11P tire leak imbalance fault This key also instructs the system to check tire pressures at more frequent intervals The Run Flat feature will automatically de select after 10 minutes CAUTION Pressing the RUN FLAT key may override Low...

Page 157: ... Repeated pressure will lock the display on each individual channel so that any channel may be monitored continuously and then return to the no display condition C0029848 TPCS LOGO MARK Indicates system power ON at vehicle start up Note All symbols on the display will light momentarily upon start of the vehicle C0029849 CHANNEL INDICATORS The rings inside the tires of the configuration indicators ...

Page 158: ...ne in emergency situations only Note Mark the alignment of the tire valve stem to the hub if necessary Note When removing hoses store in a clean dry location to prevent contamination and or damage WHEEL REMOVAL STEER 1 Remove Tire Hose Disconnect tire hose from valve stem then disconnect hose from wheel valve 2 Cap Wheel Valve in the hubcap to prevent wheel valve contamination Rotate the tire with...

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: ...nds to an increase in engine speed Accel and the Set position press the bottom corresponds to a decrease in engine speed Decel Note Under specific circumstances this switch can also be used to activate cruise control For details concerning the Initial Set Using Resume Switch feature refer to the V MAC Support Software User s Guide Speed Control Switch Activates the cruise control system Setting Cr...

Page 161: ...he process of setting cruise control must be repeated in order to re activate cruise control unless the Initial Set Using Resume Switch feature is enabled To temporarily disengage cruise control disengage the clutch or apply the service brakes Note If cruise control is temporarily disengaged using the clutch or service brakes press the Resume switch to resume the previously programmed speed ...

Page 162: ...tant that you take the time to become familiar with your engine brake before putting it into operation WARNING Operation of any vehicle on wet or slippery roads requires extreme caution Because the engine brake converts the engine to a retarding device it should NOT be used on wet or slippery roads if the vehicle has a single driving axle or if it has tandem driving axles that are lightly loaded U...

Page 163: ...dal is not depressed manual shift transmissions only The engine speed is at least 900 rpm Vehicle must be in gear Vehicle speed should be greater than 8 km h If the engine brake is active the engine brake will automatically be deactivated by depressing either the accelerator or the clutch or if the engine speed drops below 900 rpm As soon as all of the engine brake active conditions are again true...

Page 164: ...s the default mode Consult your V MAC IV Operator s Manual for more information about this option Your local MACK dealer can change the current selection The engine brake s ability to control maximum vehicle speed is limited to the selected retarding power of the engine brake If the engine brake dash mounted control switch is set to the LOW position only half of the available braking power is used...

Page 165: ...se there is no substitute for driver training by a qualified specialist The following information is intended as a guideline to safe and appropriate use of the MACK PowerLeash Engine Brake It is difficult to describe every possible driving condition Certain circumstances may require a more conservative approach than will be described When encountering any new driving route or situation err on the ...

Page 166: ...or a certain vehicle and load condition a control speed may be established for a given descent The control speed is the vehicle speed at which the retarding forces of air drag rolling resistance and engine brake power are equally balanced by the natural force of gravity that causes the vehicle to accelerate down the hill resulting in a steady controlled vehicle speed The additional vehicle slowing...

Page 167: ...rake to the HIGH position and now it is possible to descend the same grade in sixth gear to maintain a steady 35 mph at 2 000 engine rpm CAUTION The maximum allowable engine speed is listed on the warning label on the sun visor Do NOT exceed 2 300 rpm C0029334 1 Descent Speed without MACK Engine Brake ...

Page 168: ...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 in some situations the engine should not be used at all As always approach untested driving conditions with caution Avoid use of the MACK PowerLeash Engine Brake in the...

Page 169: ...d conditions and make adjustments to engine brake switch position and vehicle speed as necessary Always test the LOW power position setting before moving to the HIGH position Your MACK PowerLeash Engine Brake and ABS control systems are designed to work together for optimized vehicle control The engine brake function may be modified or interrupted briefly in the event of pending wheel lock CAUTION...

Page 170: ...low air pressure occurs in either circuit In tractor applications the Trailer Supply Valve red octagonal knob will immediately pop out in the event of a trailer breakaway or sudden trailer air line failure which will apply the trailer spring brakes In the event of a slow leak in the trailer air system the trailer supply valve will pop out when system Pressure reaches 70 psi This protects the tract...

Page 171: ...ter is indicated If brakes are found to be out of adjustment the vehicle must be taken to the nearest repair facility to have the problem investigated and corrected DANGER Automatic slack adjusters should not be manually adjusted in an effort to correct excessive pushrod stroke because this condition indicates that a problem exists with the automatic adjuster with the installation of the adjuster ...

Page 172: ...ng the driver s seat When parking on a grade use wheel chocks under the rear wheels or turn the front wheels to the curb Do not leave diesel engine vehicles in gear if the vehicle should move the engine may start by heat of compression Check brake adjustment frequently to be sure that the brakes will lock and hold the vehicle when parked Do not use the parking brake to slow or stop the vehicle whe...

Page 173: ...on MACK Road Stability Advantage If Equipped The MACK Road Stability Advantage RSA is based on the Bendix ABS 6 Advanced with ESP Electronic Stability Program System The RSA system aids the operator in maintaining control of the vehicle in the event of a jackknife or rollover situation by applying select brakes and reducing engine power as required by the specific situation The RSA system which is...

Page 174: ...mentioned above may affect proper function of the RSA system resulting in a loss of vehicle control due to system intervention at inappropriate times Vehicle Modifications Alterations to the vehicle such as changes to the wheel base either lengthening or shortening the addition of an auxiliary lift axle or removal of a factory installed auxiliary lift axle or major body changes such as conversion ...

Page 175: ...ts using the original equipment mounting brackets and tightening torque specifications 20 N m 15 lb ft The following additional changes MUST NOT be made to an as built vehicle Changes to maximum steering angle to the left or right Changes to steer axle and or drive axle track width Changing the front and or rear brake drums to drums having a different flange thickness Tire Size Calibration The ECU...

Page 176: ...degree to which transient signals are coupled into the vehicle system Note Whenever new electrical equipment is installed it is the obligation of the installer to ensure that the new equipment does not interfere with the proper operation of all other electrical systems on the vehicle If new electrical equipment is installed a vehicle checkout procedure should be performed 1 Perform the checkout pr...

Page 177: ...tivate any trailer auxiliary equipment Automatic Traction Control ATC If Equipped W3001113 Automatic Traction Control ATC provides improved traction on slippery surfaces by reducing wheel spin The system operates automatically as follows If a drive wheel starts to spin ATC applies air pressure to the brake of the spinning wheel Doing this transfers engine torque to the wheels that have better trac...

Page 178: ...ction is needed This function is activated with the ATC mode switch which is located on the dashboard The heavy mud snow function increases available traction by increasing permissible wheel spin When the operator selects the heavy mud snow function the ATC indicator lamp blinks continuously The ATC lamp stops blinking when the ATC mode switch is turned off ...

Page 179: ...at the instruments frequently When problems develop take prompt steps to correct them Shutting Down the Engine After a hard run allow the engine to idle three minutes before shutdown to stabilize the temperature of all engine parts Quick shutdowns can cause engine damage and prevent the turbocharger from being properly lubricated For additional options see Shutting Down the Engine page 174 General...

Page 180: ...the engine CAUTION If the engine does not start immediately limit cranking periods to 30 seconds to avoid overheating and damaging the starter CAUTION Do not rev the engine at start up Turbocharger damage may result because lubricants need time to establish a film between moving parts Push Button Starters Put the key in the ignition switch Turn the key clockwise to the first click about two o cloc...

Page 181: ...ter may be damaged Wait at least five seconds before attempting to restart the engine If the engine does not start immediately limit cranking periods to 30 seconds to avoid overheating and damaging the starter DO NOT rev the engine at start up Turbocharger damage may result Lubricants need time to establish a film between moving parts 2 After the engine has started warm the engine until the coolan...

Page 182: ...ile smoking or in the presence of flames sparks or hot surfaces or when working on an operating engine Failure to follow these precautions can result in fire To guard against burns from direct contact with hot fuel wear adequate protective clothing face shield heavy gloves and apron etc when working on a hot engine WARNING DO NOT work near the fan with the engine running The engine fan can engage ...

Page 183: ...needed to properly prime the system Note There are NO bleed nipples to be opened in order to prime the fuel system 3 Lock the hand primer pump by retracting it into the housing and turning it clockwise 4 Start the engine and run it at an increased idle speed for approximately 5 minutes to remove any remaining air in the system 5 Check the fuel system for leaks Note If the engine does not start fol...

Page 184: ... become contaminated with combustion by products Cold weather operations place added demands on a diesel engine When operating in cold climates particularly in stop and go operations PTO operations or periods of extended engine idling minimum operating temperature must be maintained to prevent engine damage resulting from valve varnishing and carbon build up Note Many accessories are available for...

Page 185: ... air pressure for restarting the engine V MAC IV Shutdown Option Idle Cooldown This feature provides a means of cooling down the engine and turbocharger If the idle cooldown option is enabled using VCADS Pro MACK 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 O...

Page 186: ... Override Switch on the instrument panel shortly after the vehicle sounds the engine shutdown alarm allows 30 additional seconds of operation This process can be repeated several times to safely park the vehicle CAUTION Continuously overriding the shutdown system may result in severe engine damage Engine Shutdown Indicator During normal operating conditions this indicator should illuminate as soon...

Page 187: ...fully charged in cold weather Use the correct grade of oil for the prevailing winter temperature Drain the fuel tanks and filters regularly to prevent water accumulation in the fuel system This accumulation can freeze in fuel tanks fuel lines and filters WARNING Do NOT under any circumstances add gasoline alcohol used oil or additives with metallic particles to the fuel If the fuel gels and starts...

Page 188: ... The location of the engine heater power receptacle varies according to vehicle design C0029338 1 Engine Block Heaters Engine Heater Benefits Eliminates cold weather starting problems Increases engine life significantly by keeping the engine warm and avoiding costly excessive idling Prevents external water leaks caused by excessive cold Allows the cab to heat more quickly Reduces the temperature a...

Page 189: ...ratures power loss excessive fan usage reduced fuel economy and possible engine or charge air cooler damage The use of any other type of device such as a radiator cover cardboard or similar material is not approved by Mack Trucks Inc 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...

Page 190: ...F 35 C 30 F 40 C 40 F Can be Used Recommended Recommended CAUTION Winter treatments are NOT RECOMMENDED for vehicles which only operate intermittently in cold climates Sustained temperatures must be below 25 C 13 F CAUTION Never fully close the winterfront if equipped with viscous fan drive For more information on winterfronts please refer to the Maintenance and Lubrication Manual ON BOARD SCALES ...

Page 191: ...iler suspension loads to an accurate on ground weight By comparing empty and loaded axle group weights with empty and loaded suspension pressures the scale can be calibrated to display accurate weights for any air suspension load For more information on this optional feature please refer to the Air Weigh Installation Calibration and Operations Manual 901 003 000 ...

Page 192: ...use the air suspension control switch to exhaust air from the suspension air bags until fifth wheel and trailer height match CAUTION Failure to match fifth wheel height with trailer height will result in the trailer being improperly connected 6 Back under the trailer slowly until the trailer king pin engages Back slowly to avoid hitting the king pin too hard and stop as soon as the king pin is loc...

Page 193: ...s in the lock position and make sure the safety latch is in position over the locking lever 12 After ensuring that the trailer is properly connected raise the landing gear to its maximum height 13 If wheel chocks were placed at the trailer wheels remove the chocks and store CAUTION If equipped with an air suspension do NOT operate the vehicle with the suspension air bags deflated Always reinflate ...

Page 194: ...onnector Connect the glad hands to the dummy couplers at the back of the tractor and install the trailer electrical connector into the receptacle provided at the back of the cab CAUTION Make sure the trailer air lines and electrical cord are properly suspended so they will not become tangled or damaged while the tractor is being driven WARNING Keep legs and feet clear of the tractor rear wheels to...

Page 195: ...on use the air suspension control switch to reinflate the suspension air bags 14 Release the parking brakes and drive the tractor forward until the tractor is clear of the trailer CAUTION If equipped with an air suspension do NOT operate the vehicle with the suspension air bags deflated Always reinflate the suspension air bags after coupling or uncoupling a trailer ...

Page 196: ... or maintain governed engine speed when applying full throttle Allowing the engine to lug causes excessive strain on the engine which could damage pistons rings cylinder walls or bearings However be sure not to overspeed the engine DANGER Always select the proper gear ratio BEFORE descending a grade to avoid a runaway vehicle and to stay within safe and legal speed limits Do NOT coast down hills G...

Page 197: ...in extreme reduction gears Always use the same gear going downhill as uphill This will reduce brake wear and prevent damage to the engine from overspeeding Engine Temperature Before entering high speed traffic conditions allow the engine to reach normal operating temperature A normal operating range is between 77 C and 104 C 170 F and 220 F for stationary vehicles Clutch If Equipped To avoid shock...

Page 198: ... Never allow your foot to ride the clutch pedal when the clutch is engaged This will cause premature failure and increased clutch wear 6 As the vehicle gains speed continue shifting until the transmission is in the highest gear possible with engine in operating range Note When the vehicle is equipped with a torque limiting device the engine must be warmed up to operating temperature before attempt...

Page 199: ...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: ...gages sooner in the pedal stroke than conventional non assist systems To avoid system damage be careful not to engage the clutch brake during normal shifting 2 Shift the transmission into first or reverse gear engage the clutch and accelerate The clutch brake is only to be used when the vehicle is stopped and is shifted into first or reverse gears It is not designed to be used as an upshifting aid...

Page 201: ...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: ...to the operator DANGER PTO units are driven by engine or drivetrain components flywheel crankshaft transmission Do not attempt to service the PTO and related units unless the engine is shut down DANGER Always keep body parts and loose fitting clothing out of the range of drivetrain components or personal injury may result DANGER Always be aware of the current PTO status engaged or disengaged and t...

Page 203: ...of the PTO output rated torque horsepower Side Mounted PTO Locations The first choice location for Side Mounted PTOs is either of the PTO openings on the main box The second choice which is the compound PTO opening is restricted to those applications specifically requiring multi speed PTOs with reverse capability such as some mechanical winches or unique speed or multiple PTO requirements However ...

Page 204: ... s lubricating properties and is NOT recommended CAUTION To avoid transmission damage the vehicle must be completely stopped before being shifted from REVERSE to any forward speed and vice versa CAUTION Never coast with the transmission in neutral Never coast with the clutch depressed Shifting Instructions for Allison Automatic Transmissions Please refer to the applicable Allison automatic transmi...

Page 205: ...a single shift lever using the traditional H pattern Upshift Start out in first gear and shift up to second third fourth fifth and sixth gears double clutching from one gear to the next Downshift Downshift in reverse order sixth through first double clutching through each gear C0029341 T306G TRANSMISSION RATIOS Gear Ratio 1 7 50 2 4 08 3 2 41 4 1 50 5 1 00 6 0 71 Reverse 8 84 ...

Page 206: ... HI auxiliary compound section is controlled by an air shift range selector valve located on the shift lever The LO range has two low gear ratios In HI range there are six forward gears which can be shifted in the normal manner but remember to double clutch whether moving up or down through the gears For normal highway use start in HI range first gear and shift through second third fourth fifth an...

Page 207: ...9342 TM308 TRANSMISSION RATIOS Ratios Gear Main Box LO Range Hi Range First Lo 17 77 Second Lo 10 94 First Hi 6 57 Second Hi 4 05 Third Hi 2 54 Fourth Hi 1 57 Fifth Hi 1 00 Sixth Hi 0 71 Reverse Lo 18 36 Reverse Hi 6 79 ...

Page 208: ...n the shift lever The LO range has two low gear ratios In HI range there are six forward gears which can be shifted in the normal manner but remember to double clutch whether moving up or down through the gears For normal highway use start in HI range first gear and shift through second third fourth fifth and sixth The ratio step between fifth and sixth is smaller than all the other ratio steps Th...

Page 209: ... 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: ... 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 Fourth Hi 1 57 Fifth Hi 1 00 Sixth Hi 0 71 ...

Page 211: ... are six forward gears which can be shifted in the normal manner but remember to double clutch whether moving up or down through the gears For normal highway use start in HI range first gear and shift through second third fourth fifth and sixth The ratio step between fifth and sixth is smaller than all the other ratio steps The three gears in LO range are designed for off highway use and in slow m...

Page 212: ...309 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 Fifth Hi 1 00 Sixth Hi 0 71 Reverse Lo 25 67 Reverse Hi 6 79 ...

Page 213: ...rs For normal highway use start in HI range first gear and shift through second third fourth fifth and sixth The ratio step between fifth and sixth is smaller than all the other ratio steps The three gears in LO range are designed for off highway use and in slow moving operations curb pouring material spreading heavy load steep grade Only start in the lowest gear necessary to move the vehicle The ...

Page 214: ...TIOS Ratios Gear Main Box LO Range Direct Range Reverse First Lo 25 21 22 12 Second Lo 15 52 13 62 Third Lo 9 73 8 54 Fourth Lo 5 30 Fifth Lo 3 37 Sixth Lo 2 40 First Hi 6 57 Second Hi 4 05 Third Hi 2 54 Fourth Hi 1 57 Fifth Hi 1 00 Sixth Hi 0 71 ...

Page 215: ...cessary to start in LO speed gear or first second gears Note that LO speed gear was designed for off highway use such as paving material spreading or heavy load steep grade conditions The HI range has four forward gears that can be shifted in the standard manner Remember however to double clutch when moving up or down through these gears REVERSE can be used in LO range only Upshift Under normal hi...

Page 216: ... second and first double clutching between gears T309 and T309L Reverse Reverse can be used in LO range only T309LR Reverse Reverse can be used in LO and HI range To make a range shift in reverse bring the truck to a complete stop Flip the range selector to the range desired preselect Move the shift lever out of reverse through NEUTRAL and then back into reverse again As the lever moves through NE...

Page 217: ...SMISSION RATIOS Gear Main Box LO Range HI Range LO 13 74 1 5 7 35 1 94 2 6 5 25 1 39 3 7 3 78 1 00 4 8 2 69 0 71 R 24 24 6 41 Preferred Methods for Engaging T309 Eighth Gear or any Hi Range Gear for Output Shaft Driven Power Take Off PTO Operation Note OPTIONAL RANGE ENGAGEMENT INDICATOR LAMP If the vehicle is so equipped an indicator lamp located in the cab will illuminate to indicate that the ra...

Page 218: ...t the transmission to EIGHTH gear 11 Release the clutch pedal to begin PTO operation Method 2 PTO Operation with Wheels ON the Ground 1 Position the vehicle for power take off operation 2 Stop the vehicle and apply the spring brakes 3 Keep the vehicle wheels on the ground 4 Shift the transmission to NEUTRAL 5 Place the range selector to HIGH 6 Fully depress the clutch pedal and shift the transmiss...

Page 219: ... the standard manner Always remember however to double clutch whether moving up or down through these gears Reverse gear can be used in LO range only Upshift With the shift lever in NEUTRAL flip the air shift range selector down to LO range Then shift the transmission into first gear Shift up to second third fourth and fifth speed gears double clutching between the gears When maximum engine RPM ha...

Page 220: ... 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 complete stop Flip the range selector lever to range desired preselect Move the shift lever out of reverse through NEUTRAL and then back into reverse again As the lever moves through NEUTRAL the range shi...

Page 221: ...0ME and T310MLR Shifting Instructions CAUTION Make sure air pressure is at least 90 psi and unit is at operating temperature before making range shifts Always start in LO range This also applies to dynamometer testing When the truck is stationary do NOT shift into HI range and then start moving the truck Otherwise damage to the synchronizer may result ...

Page 222: ...ift selector in LO range Upshift to second gear 2 6 on shift pattern diagram LO range in the normal manner double clutching When ready to upshift again depress the clutch pedal and release the accelerator pedal in the normal manner Repeat this shifting pattern through the remaining gears up to fourth speed 4 8 on shift pattern diagram When maximum engine RPM has been reached in fourth gear flip th...

Page 223: ... as desired Select lowest lever gear position Release and depress clutch pedal Select desired gear C0029348 T310M AND T310ME TRANSMISSION RATIOS Gear Main Box LO Range HI Range Reverse LOLO 17 35 15 22 LO 11 40 10 00 1 5 7 45 1 94 6 54 2 6 5 33 1 39 4 67 3 7 3 83 1 00 3 37 4 8 2 78 0 73 2 44 ...

Page 224: ...iven Power Take Off Operation After positioning the vehicle for power take off operation 1 Shift the transmission to NEUTRAL 2 Engage power take off drive 3 Move range selector to HI range 4 Disengage engine clutch 5 Select tenth gear 8 on the shift marker plate for T310M or T310MLR 6 Engage clutch when power take off operation is desired CAUTION When the truck is stationary do NOT shift into HI r...

Page 225: ...leasing it or by backing off the throttle and reapplying it The splitter switch must not be actuated either up or down until IMMEDIATELY before the driveline torque is relieved When making a RANGE SHIFT it is important to preselect the range shift This means that the range selector must be moved to its next position up or down BEFORE the gearshift lever is moved Then move the gearshift lever throu...

Page 226: ...ed then move the splitter switch to LO as you move the shift lever through NEUTRAL to the next higher gear Note that the splitter switch must not be actuated down to the LO position until the main box is in NEUTRAL Downshift Shift from eighth HI split to eighth LO split then seventh HI split seventh LO split and so on double clutching between the gears until you reach fifth LO split While in fifth...

Page 227: ...e range selector to the range desired preselect Move the shift lever out of reverse through NEUTRAL and then back into reverse again As the lever moves through NEUTRAL the range shift will be completed CAUTION To avoid transmission damage do NOT change range while moving in REVERSE C0029349 ...

Page 228: ... LO HI 1 18 1 18 1 18 7 HI HI 1 00 1 00 1 00 8 LO HI 0 84 0 84 0 84 8 HI HI 0 71 0 71 0 71 R LO LO 28 98 15 91 15 91 R HI HI 6 41 3 52 3 52 Rear Case Side Mounted PTO Operating Procedures T313 T313L and T313LR When engaging the PTO 1 Select LO split using the splitter switch and select LO range using the range selector Note The transmission MUST be in LO range and LO split at all times during PTO ...

Page 229: ...e synchro clutch back to LO range 5 Move the shift lever to the desired main gear box ratio 6 Release the parking brakes 7 Release the clutch pedal to engage the clutch 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 Always start in LO range This also applies to dynamometer test...

Page 230: ...gage the clutch and accelerate to governed speed Shift up through first second third fourth speed gears double clutching between the gears To continue while in fourth gear LO split flip the range selector up to HI range preselect then move the shift lever through NEUTRAL to fifth gear As the lever moves through NEUTRAL the range shift to HI will be completed You are now in fifth gear LO split HI r...

Page 231: ... should be heard To downshift from a LO split gear to the next lower gears HI split in HI range as engine speed falls move the splitter switch to HI as you move the shift lever through NEUTRAL to the next lower gear Note that the splitter switch must not be actuated up to the HI position until the main box is in NEUTRAL Remember to double clutch between gears T31321 and T313L21 Reverse Reverse can...

Page 232: ...6 42 1 LO LO 8 78 8 78 8 78 2 LO LO 6 28 6 28 6 28 3 LO LO 4 52 4 52 4 52 4 LO LO 3 22 3 22 3 22 Range Shift Here 5 LO HI 2 29 2 29 2 29 5 HI HI 1 94 1 94 1 94 6 LO HI 1 64 1 64 1 64 6 HI HI 1 39 1 39 1 39 7 LO HI 1 18 1 18 1 18 7 HI HI 1 00 1 00 1 00 8 LO HI 0 84 0 84 0 84 8 HI HI 0 71 0 71 0 71 R LO LO 15 91 28 98 15 91 R HI HI 3 52 6 41 3 52 ...

Page 233: ... NEUTRAL to the next desired gear position As the lever passes through NEUTRAL the range shift will be completed Upshift For purposes of explaining the shifting procedures through ALL gears assume that the vehicle has a full load and will climb a slight grade To prepare for moving the vehicle position the shift lever in NEUTRAL select LO split using the splitter switch and select LO range using th...

Page 234: ...O to HI As the shift lever moves through NEUTRAL the range shift to LO will be completed You are now in fourth gear HI split LO range Continue downshifting using the shift lever and splitter in the normal manner until you reach LO speed gear LO range LO split To downshift from HI split to LO split in the same gear as engine speed falls move the splitter to LO preselect then release and reapply the...

Page 235: ...224 OPERATION C0029351 ...

Page 236: ... LO LO 6 28 6 28 6 28 2 HI LO 5 33 5 33 5 33 3 LO LO 4 52 4 52 4 52 3 HI LO 3 83 3 83 3 83 4 LO LO 3 22 3 22 3 22 4 HI LO 2 73 2 73 2 73 Range Shift Here 5 LO HI 2 29 2 29 2 29 5 HI HI 1 94 1 94 1 94 6 LO HI 1 64 1 64 1 64 6 HI HI 1 39 1 39 1 39 7 LO HI 1 18 1 18 1 18 7 HI HI 1 00 1 00 1 00 8 LO HI 0 84 0 84 0 84 8 HI HI 0 71 0 71 0 71 R LO LO 15 91 28 98 15 91 R LO HI 13 49 24 58 13 49 R HI HI 3 ...

Page 237: ...pound NEUTRAL control valve to the ON position which moves the synchro clutch to a NEUTRAL position 6 Engage the PTO 7 Move the main box shift lever to the desired ratio 8 Release the clutch pedal to engage the clutch 9 Operate the PTO driven load When disengaging the PTO 1 Depress the clutch pedal to disengage the clutch 2 Move the main box shift lever to NEUTRAL 3 Disengage the PTO 4 Move the da...

Page 238: ...ransmission range clutch engagement is heard 6 Disengage the engine clutch 7 Select 18th speed gear for T318LR 8 Engage the clutch when power take off operation is desired Method 2 After positioning the vehicle for power take off operation and with vehicle wheels on the ground 1 Shift the transmission to NEUTRAL 2 Move the range selector to HI range 3 Disengage the engine clutch and select REVERSE...

Page 239: ...ugh NEUTRAL to the next desired gear position As the lever passes through NEUTRAL the range shift will be completed Upshift For purposes of explaining the shifting procedures through ALL gears assume that the vehicle has a full load and will climb a slight grade To prepare for moving the vehicle position the shift lever in NEUTRAL select LO split using the splitter switch and select LO range using...

Page 240: ...to HI As the shift lever moves through NEUTRAL the range shift to LO will be completed You are now in fourth gear HI split LO range Continue downshifting using the shift lever and splitter in the normal manner until you reach LO speed gear LO range LO split To downshift from HI split to LO split in the same gear as engine speed falls move the splitter to LO preselect then release and reapply the a...

Page 241: ...230 OPERATION C0029352 ...

Page 242: ...7 45 2 LO LO 6 28 6 28 6 28 2 HI LO 5 33 5 33 5 33 3 LO LO 4 52 4 52 4 52 3 HI LO 3 83 3 83 3 83 4 LO LO 3 22 3 22 3 22 4 HI LO 2 73 2 73 2 73 Range Shift Here 5 LO HI 2 29 2 29 2 29 5 HI HI 1 94 1 94 1 94 6 LO HI 1 64 1 64 1 64 6 HI HI 1 39 1 39 1 39 7 LO HI 1 18 1 18 1 18 7 HI HI 1 00 1 00 1 00 8 LO HI 0 84 0 84 0 84 8 HI HI 0 71 0 71 0 71 R LO LO 15 91 28 98 15 91 R LO HI 13 49 24 58 13 49 R HI...

Page 243: ...compound NEUTRAL control valve to the ON position which moves the synchro clutch to a NEUTRAL position 6 Engage the PTO 7 Move the main box shift lever to the desired ratio 8 Release the clutch pedal to engage the clutch 9 Operate the PTO driven load When disengaging the PTO 1 Depress the clutch pedal to disengage the clutch 2 Move the main box shift lever to NEUTRAL 3 Disengage the PTO 4 Move the...

Page 244: ...ransmission range clutch engagement is heard 6 Disengage the engine clutch 7 Select 18th speed gear for T318L R 21 8 Engage the clutch when power take off operation is desired Method 2 After positioning the vehicle for power take off operation and with vehicle wheels on the ground 1 Shift the transmission to NEUTRAL 2 Move the range selector to HI range 3 Disengage the engine clutch and select REV...

Page 245: ... 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 Both types of axle shafts can be removed without removing or d...

Page 246: ...w power to the axle with traction Feathering brakes should not be done with power divider lockout engaged Note For vendor axles see the vendor manual furnished with the vehicle Engaging the Power Divider Lockout Normally the Power Divider switch is in the OUT disengaged position In poor traction conditions it may be necessary to provide positive through drive to both axles by flipping the switch t...

Page 247: ...oller bearings HI LO engagement is effected by means of a sliding clutch A conventional fork spans the sliding clutch and moves in response to movement of the gearshift hand control lever or air control valve A planetary gear type center differential is incorporated to provide front wheel drive availability at all times without requiring driver attention However for extremely slippery conditions a...

Page 248: ...0 999 2 593 0 838 TC S 1510 0 768 1 992 0 838 TC S 152 0 999 2 593 1 000 C0029904 TC S 1520 0 768 1 992 1 000 Model HI Range LO Range Front Drive TC S 25 1 36 2 593 0 965 TC 25 Series SHIFT PATTERN TC S 250 1 045 1 992 0 965 TC S 251 1 36 2 593 0 838 TC S 2510 1 045 1 992 0 838 TC S 252 1 36 2 593 1 000 C0029904 TC S 2520 1 045 1 992 1 000 ...

Page 249: ...rder to complete the exhaust aftertreatment conditioning cycle Exhaust temperatures will also elevate slightly but remain much lower than those reached during regeneration and present no danger If a compatible driver display is available a message will be displayed when the conditioning cycle is in progress The message indicated in the driver s display will be ATS Conditioning in Progress No Actio...

Page 250: ...O Premium Plus or VDS 4 will adversely affect performance efficiency and durability of the DPF system and the engine to the point where the engine may not run at all Manufacturer s warranties will also be rendered void due to usage of improper fuel Unapproved fuel additives including engine oil are NOT permitted Mack Trucks Inc offers two different types of DPF systems Conventional DPF passive reg...

Page 251: ...perature inside the unit to the point where the soot oxidation takes place Conventional exhaust aftertreatment systems are used in highway and certain vocational applications TRU exhaust aftertreatment systems are used mainly in refuse collection applications Depending on how the vehicle is set up regeneration can occur while the vehicle is being driven referred to as a moving regeneration or when...

Page 252: ...n 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: ...le The conditioning cycle is controlled by the Engine ECU and will start and stop automatically as needed The ATS conditioning is required to maintain normal exhaust aftertreatment system function and should not be stopped ATS conditioning will not occur on TRU DPF systems During these events the engine speed will increase to approximately 1050 1400 rpm for non PTO in order to complete the exhaust...

Page 254: ...ilter DPF 4 Aftertreatment DEF Tank Diesel Exhaust Fluid DEF is a reactant that s key to the SCR process It s a nontoxic ultra pure solution of urea and ultra pure water Urea is a compound of nitrogen that turns to ammonia when heated It is used in a variety of industries perhaps most commonly as a fertilizer in agriculture The fluid is non flammable and is not dangerous when handled as recommende...

Page 255: ... temperatures will increase during a parked regeneration When parking the vehicle to perform a parked regeneration keep away from any flammable materials vapors or structures DANGER Exhaust gases and components can be at extremely high temperatures during regeneration When parking the vehicle keep away from any flammable materials vapors or structures DANGER The temperature of the exhaust system c...

Page 256: ...missions of another pollutant soot also known as particulate matter or PM SCR works by injecting Diesel Exhaust Fluid DEF into the exhaust DEF is a solution of ultra pure water and urea DEF works with the heat of the exhaust and a catalyst to convert NOx into nitrogen and water vapor two harmless and natural components of the air we breathe The end result is cleaner air excellent fuel efficiency a...

Page 257: ...tertreatment DEF Dosing unit and SCR catalyst The advantage of using DEF is that it enables the engine to use less EGR and higher oxygen levels for better combustion while meeting the EPA NOx emissions requirement By using DEF we avoid the disadvantages of increasing EGR to massive levels This results in better fuel economy from your Mack engine W2055490 Vertical SCR side inlet W2055491 Vertical S...

Page 258: ...size W2055493 Horizontal SCR compact size CAUTION Do not put diesel fuel in the Aftertreatment DEF tank Diesel fuel if sprayed into the hot exhaust along with the DEF could ignite explosively causing a fire resulting in personal injury or damage to the exhaust system ...

Page 259: ...s meeting ISO 22241 standards and certified by the American Petroleum Institute The container must display the API certification seal Never use agricultural or industrial grade urea Use of fluids other than API certified Diesel Exhaust Fluid will compromise aftertreatment system performance increase emissions and may impact your product warranties Never dilute DEF with water or any other fluid It ...

Page 260: ...hings to know about spilled Diesel Exhaust Fluid DEF If DEF solution comes into contact with the skin rinse with plenty of water and remove contaminated clothing If DEF solution comes into contact with the eyes rinse for several minutes and call for medical help if necessary If inhaled breathe fresh air and call for medical help if necessary Do not allow the DEF solution to come into contact with ...

Page 261: ...the engine will resume normal power Note DEF tanks are sized for a two to one fuel to DEF ratio in order to meet US 2010 requirements Diesel Exhaust Fluid DEF Availability DEF will be available in 2 5 gallon containers 55 gallon drums 275 gallon IBC and in bulk storage for fleet locations truck stops and dealerships All major truck stops dealers and distributors will carry DEF DEF will freezes bel...

Page 262: ...densation may be visible during a cold start If black exhaust smoke is visible during engine operation this indicates a problem with the exhaust aftertreatment system Take the vehicle to an authorized Mack Truck dealer immediately Vehicles equipped with a 2010 emission compliant engine have an exhaust aftertreatment system which includes a Selective Catalytic Reduction SCR system and a Conventiona...

Page 263: ...tment DEF Return Valve The ACM also monitors the following values in the exhaust aftertreatment system Aftertreatment DEF Dosing Pressure Aftertreatment DEF Tank Temperature Aftertreatment DEF Tank Level Aftertreatment DPF Inlet Outlet Temperature Aftertreatment DEF Tank Level Sensor Aftertreatment DPF Differential Pressure NOX Sensors The ACM is a stand alone module Depending on your configuratio...

Page 264: ...148 DPF Smart Switch 1 Upper Position Regeneration Position 3 Down Position Inhibit Position if equipped 2 Middle Position Neutral Position CAUTION During the Aftertreatment DPF Regeneration the exhaust gas temperature will be elevated DO NOT park the vehicle with the exhaust outlet near flammable objects such as trees awnings etc that could be damaged by elevated exhaust gas temperatures ...

Page 265: ...injecting additional fuel into the dpf system On chassis equipped with a US07 aftertreatment system DPFs needed an active regeneration that included this injection of fuel With the addition of the SCR system active regenerations are no longer needed for EPA2010 Parked Regeneration The Aftertreatment DPF Regeneration system is self monitoring Under certain duty cycles driver action is needed to per...

Page 266: ...tems the engine speed may ramp as high as 1 250 rpm 5 Parked regeneration will take between 30 and 45 minutes to complete 6 After regeneration has completed and the exhaust temperature has returned to normal the HEST indicator will shut off 7 To stop regeneration press the switch down to the inhibit position if equipped When the bottom of the switch is illuminated regeneration is stopped The switc...

Page 267: ...ation However if a parked regeneration is stopped too many times the vehicle must be taken to a MACK service facility The service facility will use a service tool to manually initiate the regeneration WARNING The temperature of the exhaust system components during the regeneration process 350 degrees C 660 F The exhaust gas leaving the system can reach 505 degrees C 930 F Various factors including...

Page 268: ...n the vehicle speed will decrease down to 16 kph 10 mph below the current speed until the driver releases the switch back to the neutral MIDDLE position 2 Vehicle Stationary and then Moving If the vehicle is stationary with the DPF Smart Switch in the locked DOWN position and the driver then begins to move the truck the vehicle speed will be limited to 16 kph 10 mph until the driver releases the s...

Page 269: ... been required on passenger cars for many years On Board Diagnostics OBD is a system that monitors the functions of emissions related components and alerts the vehicle operator to any detected need for an emission related repair When the systems detects a needed repair to an emissions related component it activates the Malfunction Indicator Lamp MIL The list of emissions related components can be ...

Page 270: ...aftertreatment icons are located in the instrument cluster per the following images CHU Instrument Cluster W3031621 1 Malfunction Indicator Lamp MIL 2 CHECK Lamp 3 Aftertreatment DEF Low Lamp 4 High Exhaust Temperature HEST Lamp 5 Aftertreatment DEF Tank Gauge ...

Page 271: ...inates when a parked Aftertreatment DPF Regeneration Required is initiated It also indicates high exhaust gas temperature during a passive regeneration When the HEST icon is illuminated do not park or operate the vehicle near people or any flammable materials vapors or structures W3007444 High Exhaust System Temperature HEST Icon W2029416 Aftertreatment DEF Tank Low Level Indicator DEF The Aftertr...

Page 272: ...rs Aftertreatment DEF Tank Low Level Indicator Amber Warning Lamp Inducement 12 Aftertreatment DEF Tank Level Gauge None None None 12 Aftertreatment DEF Tank Level Gauge W2029416 None None 0 Aftertreatment DEF Tank Level Gauge 4 DEF Remaining W2029415 None 25 torque reduction 0 Aftertreatment DEF Tank Gauge Insufficient DEF Pump Pressure Diesel Fuel Refueling 15 W2029415 None 8 km h 5 mph Road Spe...

Page 273: ...e Poor DEF Quality DTC Initial Detected None W3031623 None Poor DEF Quality DTC Initial Detected 10 hours None W3031623 25 torque reduction Poor DEF Quality DTC Initial Detected 20 hours Diesel Fuel Refueling 15 None W3031623 8 km h 5 mph Road Speed Limit RSL Temporary Exit from 5 mph Inducement None W3031623 25 torque reduction Note Vehicle has to be stationary before 8 km h 5 mph RSL becomes act...

Page 274: ...ation of fluids by misfilling of diesel or DEF in the wrong tank may result in vehicle malfunction Results of misfilling DEF in Diesel Tank Engine may run poorly or not at all Injectors may be damaged Exhaust system corrosion may occur between turbocharger and Aftertreatment DPF On Board Diagnostic OBD Diagnostic Trouble Codes DTC Costly repairs Results of misfilling Diesel in Aftertreatment DEF T...

Page 275: ...gers 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 Tampering DTC Initial Detected 10 hour None W3031623 25 torque reduction Tampering DTC Initial Detected 40 hours Diesel Fuel Refueling 15 None W3031623 8 km h 5 mph road speed limit Note Operator can not override th...

Page 276: ...whichever comes first Injector Lash Adjustment MP7 and MP8 Adjust Every 400 000 km 250 000 miles or 24 months whichever comes first Valve and Injector Lash adjustment MP10 Initial Adjust 100 000 km 60 000 miles or 6 months whichever comes first Injector Lash Adjustment MP10 Adjust Every 200 000 km 125 000 miles or 12 months whichever comes first Aftertreatment DPF Ash Cleaning Clean 400 000 km 250...

Page 277: ...ng daily checks and observing the equipment while in operation minor defects can be caught and corrected before they become major problems Make sure any problems are corrected before putting the equipment into operation If you have any questions concerning the proper care maintenance and lubrication of your vehicle or if you need help in developing a preventive maintenance program contact the serv...

Page 278: ...ring lubrication Operate engine at low idle for at least three minutes before increasing RPM or driving the vehicle If the engine has not been run for more than 30 days turbo pre lube procedure is necessary 1 Remove turbo air intake duct and oil line connection at turbo 2 Fill oil inlet fitting to overflow with clean engine oil 3 Using fingers at compressor wheel carefully spin and wiggle the turb...

Page 279: ...ark near factories with heavy smoke fallout for extended periods of time Bird droppings have high acid content and can damage freshly painted surfaces They should be cleaned off as soon as possible Do not spill gasoline diesel fuel oil antifreeze transmission fluid or any solvents of the like on the new finish If you do IMMEDIATELY rinse off with water DO NOT WIPE Do not scrape ice or snow from su...

Page 280: ...operations do not use muriatic acid or similar types of products to clean concrete from the cab or frame surfaces Use of these types of products will damage the paint finish and void the vehicle warranty Mack Trucks Inc has approved EL ReadyMix Truck Wash Wax for removing concrete from the vehicle surfaces This product is available on a direct ship basis from EMS For additional information contact...

Page 281: ...h a separate sponge brush This will help avoid scratching body paint with grit from other areas Rinse truck thoroughly with water and wipe dry with a soft clean chamois or all cotton towels to avoid surface scratches and water spotting CAUTION Do not clean the underside of the fenders cab chassis etc without protecting your hands and arms You may injure yourself on sharp edged parts Chassis Wash a...

Page 282: ...earcoat Use a basecoat clearcoat wax on your paint finish Polishing Polish your truck only if the paint has lost its shine and the gloss cannot be brought back with wax It is recommended to have a professional polish your truck to avoid swirl marks or damage to the painted surface Mequiar s has a complete line of waxes polishes and other cleaning and care products that are approved for use on MACK...

Page 283: ...g arrangement Note Tow pins hooks eyes etc are NOT intended for use as long term towing devices CAUTION Failure to disconnect the driveshaft remove the drive axle shaft s or lift the drive wheels off the ground before towing or pushing the vehicle can cause serious transmission damage DANGER If the drive shaft has been removed for towing DO NOT reuse bearing retainer bolts or stamped strap bolts o...

Page 284: ...MAINTENANCE AND LUBRICATION 273 C0029851 C0029852 1 Towhook Access ...

Page 285: ...le the engine is COLD prior to starting at the beginning of the work day or after the vehicle has sat approximately 2 hours At normal operating temperature engine oil temperature above 79 4 C 175 F oil level can be checked 15 minutes after shut down CAUTION Failure to wait a sufficient amount of time 2 hours if engine oil temperature is below 79 4 C 175 F or 15 minutes if oil temperature is above ...

Page 286: ...ilable 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 See illustration below C0029853 1 Engine Oil Dipstick 2 Engine Oil Fill Tube ...

Page 287: ...ng 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: ...ped 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: ...vapors are combustible and can cause an explosion or fire resulting in severe personal injury or death CAUTION Diesel powered engines for heavy duty trucks built on or after January 1 2010 are designed to operate only with Ultra Low Sulfur Diesel ULSD fuel Improper fuel use will reduce the efficiency and durability of engines permanently damage advanced emissions control systems reduce fuel econom...

Page 290: ... Do not fill more than that as the fuel needs to have room for expansion during the heat of the day BioDiesel Soy Methyl Ester SME or SOME BioDiesel fuel in blends up to a B5 concentration 5 blend is approved by Mack Trucks Inc Note 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 ...

Page 291: ...ing operated on biodiesel or other alternative fuels that are not substantially similar to specified test fuels used for certification The use of biodiesel up to a maximum of 20 B20 in and of itself will not affect the manufacturers mechanical warranty as to engine and emissions system related components except as limited below with respect to aftertreatment components provided the bio fuel used i...

Page 292: ...when checking coolant in a hot engine Wait for the engine to cool prior to checking the level whenever possible Coolant Level Check WARNING Turn the cooling system pressure cap counterclockwise slowly After the pressure has completely dissipated continue turning to remove the cap Your MACK model chassis has a pressurized plastic coolant expansion tank where quick checks of coolant level can be mad...

Page 293: ... opens Recheck level and add coolant if required Run the engine long enough to be sure the system is free of air and has the correct amount of coolant Protecting the Cooling System CAUTION The concentration of ethylene glycol or propylene glycol in the cooling system must be checked with a refractometer prior to traveling or operating in areas where subfreezing temperatures may be encountered When...

Page 294: ...ir temperature CAUTION Do NOT exceed a 60 concentration of antifreeze to water A higher percentage of antifreeze will not increase protection Concentrations over 60 adversely affect freeze protection and heat transfer rates Note Propylene glycol should be checked with a refractometer Note ALWAYS mix the water antifreeze solution before pouring it into the cooling system Note The piping arrangement...

Page 295: ...s to specifications as required Check coolant level Add fresh coolant in specified concentration as necessary Check and record degree of antifreeze concentration Add antifreeze as necessary to obtain required protection level For additional information concerning the cooling system refer to the Maintenance and Lubrication Manual Accessory Drive Belt Routing The following diagram shows the accessor...

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: ... halogen bulb with your bare hands or a dirty rag Oils and other contaminants can greatly reduce bulb life or cause the bulb to explode Open the hood To access the headlight area remove the wing nut on the headlight housing cover and lift the cover Turn the appropriate bulb holder counterclockwise to remove the bulb Reverse this procedure for reinstallation ...

Page 298: ...Rust streaks from the cap nut ball seat are an indication of looseness Refer to the Maintenance and Lubrication Manual for complete procedures concerning wheel inspection and wheel nut tightening C0029431 Look for cracks around the hand hole stud hole and wheel Look for broken studs wheel damage or improperly seated lock rings C0029432 ...

Page 299: ...truck tires Inflation Pressure To ensure maximum mileage and overall performance from your tires it is essential that they operate at the correct inflation pressure for the load carried Inflation pressure should be checked daily while the tires are cold Always use an accurate tire pressure gauge NEVER bleed air from a hot tire as it will then be underinflated Refer to the specific tire manufacture...

Page 300: ...tires daily Look for bulges cracks cuts penetrations and or oil contamination If any such damage is found the tire must be thoroughly inspected by a qualified tire inspector and repaired or discarded immediately at his discretion Also check for uneven wear If found a thorough inspection of front end parts and alignment should be made by a qualified mechanic Refer to the Maintenance and Lubrication...

Page 301: ...allowed to contact tires will soften the rubber and destroy the tire Preventive maintenance is necessary to ensure that oil leakage does not occur The following areas should be inspected on a regular basis Axle end seals Engine seals Transmission seals Drive axle seals Oil filters Oil and hydraulic lines if equipped Refer to the Maintenance and Lubrication Manual specific tire manufacturer s books...

Page 302: ...ep sparks flames cigarettes etc away from batteries at all times Protect your eyes by wearing safety goggles Be sure vehicles are NOT touching each other CAUTION To avoid damaging any electronic controllers when jump starting a V MAC vehicle always turn the ignition switch OFF before connecting the batteries 1 Connect the positive cable to positive post of discharged battery or to the positive pos...

Page 303: ...d vehicle Shut down the vehicle with the booster batteries and remove the cables in the reverse order of connection WARNING Do NOT connect the final negative connection to the frame of the stalled vehicle This would cause all current to flow through the master ground circuit breaker resulting in overload ...

Page 304: ...icle is located in the middle of the dash under the top cover The cover panels are fastened with screws Most relays and fuses are accessible from under the top cover Since the function of some fuses or relays may change for the vehicle operation refer to the list of functions that is attached beneath each panel C0029433 ...

Page 305: ...294 MAINTENANCE AND LUBRICATION C0029434 1 Front 2 Back ...

Page 306: ...nt panel Do NOT install a standard relay into the daytime running light relay socket marked either DRL MOD or Running Lamps or a short circuit in the headlight high beam circuit will result The headlight circuits are protected by SAE Type I automatic reset cycling circuit breakers that automatically interrupt then restore the flow of current through the circuit in the event of an overload This cyc...

Page 307: ...ps Direct Lps Flasher 5 10A 6 10A 7 10A 8 15A Tractor Stop Lps Dome Lps Courtesy Lps Ign Switch Air Solenoid 9 15A 10 5A 11 15A 12 10A CB Posts Communication Connector DDL Radio Battery Stud Electric Door Locks 13 20A 14 15 20A 16 10A ABS Open Heated Mirrors Vehicle Control Unit VCU 17 10A 18 10A 19 5A Clutch Switch Engine Brake Cruise On Off Set Resume Override Switch Park Brake PTO w o T2000 Spa...

Page 308: ...Sw Spare Auto shift trans or spare 53 15A 60 20A 61 20A 62 15A A C Comp Clutch 2 Power Outlet Sockets Aux sw s Spare Spare Battery 63 5A 64 10A 65 15A 67 15A ABC Gauge Cluster Cold Start VORAD Module Spare Battery 68 15A 69 10A 70 30A 71 15A Cigar Lighter Keyless Entry Module HVAC Sleeper Transmission 72 10A 74 5A HVAC Control Unit Illumination ...

Page 309: ...6 15A 37 30A 38 25A 39 30A Horn Trailer Tail Lps Engine Control Unit ign Trailer ABS Power 40 15A 41 15A 42 20A Spare Engine Compartment Back Up Lps 43 10A 44 25A 45 30A 46 20A Engine Compartment Air Dryer Htd Drain Valve Fuel Heater NOx Sensor Spare 47 10A 48 50A 49 10A 50 10A Meritor Trans EOA or Spare Sleeper Box ABS Low Beam L H 51 10A 52 15A Low Beam R H Spare Guard Dog ...

Page 310: ... MPH output connections available on the electrical equipment panel Each connection point is described below Battery Post BATT This is a 12 volt unswitched battery power connection It can be used to power external devices that require power at all times even when the key is turned off This source is protected by a 20 amp circuit breaker Ignition Post IGN This is a 12 volt switched battery power co...

Page 311: ...ATA J1708 Posts Serial Links A and B This is a serial communication interface It conforms to the SAE ATA J1708 Recommended Practice for Serial Data Communications Between Microcomputer Systems in Heavy Duty Vehicle Applications See the Warning above CB Radio Power Jack The CB radio power jacks are located on the dashboard of the day cab and on the headliner of the sleeper Power Jack This is a 12 v...

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: ...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 Neutral Power feed 15A Stop Lamp Signal 30A Tail Lamp Signal 30A Clearance Lamp Signal 30A ...

Page 314: ...LH 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 ordered Output power is included in Body Link II if auxiliary or extra dash mounted battery and ignition power dash rocker switches are ordered Spare connectors are typically used to wire unique bodybui...

Page 315: ...on s may occur with certain metric thread inch thread fastener combinations and with fastener combinations involving incompatible metric fastener systems A given thread mismatch condition can result in thread stripping and or assembly weakness leading to potential service failure thereby rendering a vehicle non operational and or unsafe for operation The specific external internal thread combinati...

Page 316: ...ls 1 pound square inch 1 8 x degrees Celsius 32 degrees Fahrenheit 83267 Imperial gallon 1 gallon U S liquid U S to SI Conversions 03937 inch 1 millimeter 6214 mile 1 kilometer 2 1134 pints U S liquid 1 liter 1 0567 quarts U S liquid 1 liter 61 024 cubic inches 1 liter 7376 pound foot 1 Newton meter 1 34 horsepower 1 kilowatt 145 pound square inch 1 kilopascal 556 x degrees Fahrenheit 32 degrees C...

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