MACK LEU Operator's Manual

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Mack

LEU Series

Mack® TerraProTM Series

(LEU Series)

Mack® TerraProTM Series

(LEU Series)

21394654

21394654 21394654

April 2010

Foreword

Thismanualcontainsinformationconcerningtheoperationand functionofthe MackLinkSystem.Theinformationinthismanual appliestovehiclesbuilt April2010andlater.Pleasekeepthismanual inthevehicleatalltimes.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay differslightlyfromtheactualvehicle.However,keycomponents addressedinthisdocumentarerepresentedasaccuratelyaspossible.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)and Mack Trucks Inc.,shouldbeinformedimmediatelyifyou believethatthevehiclehasadefectthatcouldcauseacrash,injury ordeath.

ContactNHTSAbycallingtheAutoSafetyHotlineat1(888) 327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation, Washington,DC20590,byTTYat1(800)424-9153,orvisittheir websiteatwww.nhtsa.dot.gov.

Mack Truck,Inc.

Greensboro,NCUSA

Ordernumber:PV776-21394654

Allrightsreserved.Nopartofthispublicationmaybereproduced, storedinretrievalsystem,ortransmittedinanyformsbyanymeans, electronic,mechanical,photocopying,recordingorotherwise,without thepriorwrittenpermissionof Mack Trucks, Inc.

Contents

INTRODUCTION............................................................................................................1

TOTHEOWNER..........................................................................................................1

InAppreciation..........................................................................................................1

AboutThisHandbook................................................................................................2

THEVEHICLE..............................................................................................................3

BasicConguration...................................................................................................3

VehicleManagementandControlSystem(V-MAC®).............................................3

COMPONENTIDENTIFICATION..............................................................................4

VINLocations............................................................................................................4

EngineIdentication..................................................................................................5

EngineInformationPlate...........................................................................................6

CleanIdleEngines.....................................................................................................7

TransmissionIdentication........................................................................................8

WARRANTYINFORMA TION..................................................................................10

AirBrakeSystem.....................................................................................................10

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................10

EmissionsControlSystemWarranty.......................................................................11

ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............13

FEDERALEMISSIONREQUIREMENTS............................................................14

EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................14

EmissionsControlSystemWarranty.......................................................................16

SERVICELITERATURE............................................................................................20

MACKClass8–ComponentsServiceManual.......................................................20

MACKClass8–CustomCollatedServiceManualonCD....................................20

CUSTOMERSERVICE..............................................................................................21

Call1-800-866-1177forMACKOneCall™...........................................................21

QuestionsandComplaints.......................................................................................21

Addresses.................................................................................................................22

AdditionalAssistance..............................................................................................22

REPORTINGSAFETYDEFECTS.............................................................................24

UnitedStates............................................................................................................24

Canada......................................................................................................................24

Mexico.....................................................................................................................24

EVENTDATARECORDINGDEVICES...................................................................25

SAFETYINFORMATION...........................................................................................26

SAFETYSTATEMENT..............................................................................................26

CERTIFICA TIONLABELS........................................................................................28

SafetyCerticationLabel........................................................................................28

ADVISORYLABELS.................................................................................................30

AdvisoryLabelLocations(OnV ehicle)..................................................................30

CABENTRY/EXIT.....................................................................................................39

Three-LimbContact.................................................................................................39

DriverSide...............................................................................................................41

PassengerSide.........................................................................................................43

SAFETYTIPSFORCOLDWEA THEROPERA TION.............................................44

DriverVisibility.......................................................................................................44

CabDoorSealsandKeyLocks...............................................................................45

OutsideMirrorHeater..............................................................................................45

AirHornSnowShield..............................................................................................46

FireExtinguisher(Optional)....................................................................................46

INSTRUMENTSANDCONTROLS...........................................................................47

CABINTERIOR—LEFT..........................................................................................47

CABINTERIOR—RIGHT.......................................................................................48

INSTRUMENTPANEL..............................................................................................49

Tell-T ales..................................................................................................................49

PanelArrangement...................................................................................................50

INSTRUMENTPANELGAUGELAYOUT..............................................................51

PanelsA,B,CandD...............................................................................................52

PanelE.....................................................................................................................53

PanelF.....................................................................................................................54

DPFINHIBITROADSPEEDLIMITING(RSL)...................................................62

CABCLIMATECONTROL.......................................................................................68

LIGHTCONTROLPANEL........................................................................................69

STEERINGCOLUMN................................................................................................70

CombinationStarterandElectricalSwitch..............................................................70

MISCELLANEOUSCONTROLS..............................................................................71

DomeLight..............................................................................................................71

AirHorn...................................................................................................................71

FreshAirVent..........................................................................................................72

AccessoryPowerOutlets.........................................................................................72

PRE-TRIPINSPECTIONANDDAILYMAINTENANCE......................................73

PRE-TRIP....................................................................................................................73

Pre-TripInspectionQuickList................................................................................73

OPERATION..................................................................................................................86

.....................................................................................................................................86

NewVehicleBreak-In..............................................................................................86

WINDSHIELDWASHERRESERVOIR....................................................................88

CABTILTOPERA TION.............................................................................................89

TiltingtheCab.........................................................................................................90

LoweringtheCab.....................................................................................................92

BleedingtheCabTiltSystem..................................................................................93

DOORS........................................................................................................................94

OpeningtheCabDoor.............................................................................................94

LockingtheCabDoor..............................................................................................94

Right-Side(Folding)Door.......................................................................................94

FoldingtheDoor......................................................................................................97

UnfoldingtheDoor................................................................................................100

SEATBEL TS.............................................................................................................102

SeatBeltOperation................................................................................................102

FasteningSeatBelt................................................................................................102

RIGHT-SIDERESTRAINT......................................................................................105

SEATADJUSTMENT...............................................................................................106

Right-SideFoldingSeat.........................................................................................106

AirSeat..................................................................................................................107

MIRRORSYSTEMS.................................................................................................109

MotoMirrorSystem..............................................................................................109

MACKENGINEINFORMATION...........................................................................112

PrecautionsandWarnings......................................................................................112

EngineModelDesignations...................................................................................113

CRUISECONTROLOPERATION..........................................................................114

SpeedControlSwitches.........................................................................................114

DisengagingCruiseControl...................................................................................115

MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................116

EngineBrakeSwitch..............................................................................................117

HowtheEngineBrakeisActivated.......................................................................117

CruiseControlwiththeMACKPowerLeash™EngineBrake.............................118

ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........119

OverFlatTerrain....................................................................................................119

DescendingaGrade...............................................................................................120

OnSlipperyRoadSurfaces....................................................................................122

BRAKEOPERATION...............................................................................................124

AirBrakeSystem...................................................................................................124

AutomaticSlackAdjusters....................................................................................125

ParkingBrakeSystem............................................................................................125

ParkingBrakeOperation........................................................................................126

Parking...................................................................................................................126

Anti-LockBrakeSystem(ABS)............................................................................127

AutomaticTractionControl(A TC)(IfEquipped).................................................130

WorkBrakeSystem...............................................................................................131

GOODDRIVINGHABITS.......................................................................................133

WeightRatings.......................................................................................................133

Instruments.............................................................................................................133

ShuttingDowntheEngine.....................................................................................133

GeneralObservation..............................................................................................133

STARTINGTHEVEHICLE.....................................................................................134

GeneralInformation...............................................................................................134

PushButtonStarters...............................................................................................134

AirStarters.............................................................................................................135

EngineWarm-Up...................................................................................................138

EngineIdling..........................................................................................................138

ShuttingDowntheEngine.....................................................................................139

COLDWEATHEROPERA TION.............................................................................141

ColdWeatherStartingTips....................................................................................141

EngineBlockHeaters............................................................................................142

MOVINGTHEVEHICLE—GENERALINFORMA TION...................................143

Braking...................................................................................................................143

EngineTemperature...............................................................................................143

TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................145

StatusLights..........................................................................................................148

TransmissionModuleLocation.............................................................................149

AXLES.......................................................................................................................150

RearAxlesOtherThanMACK.............................................................................150

MACKRearAxles.................................................................................................150

EngagingthePowerDividerLockout....................................................................151

ExtendedIdlingandAftertreatmentSystemConditioning.......................................154

Mack,US10EmissionsSolution.................................................................................155

DIESELPARTICULA TEFILTERS.........................................................................155

ExhaustAftertreatmentSystem.................................................................................158

SafetyInformation.................................................................................................159

ExhaustAftertreatmentSystemComponentsand................................................160

SelectiveCatalyticReduction(SCR)....................................................................160

DieselExhaustFluid(DEF)...................................................................................162

AftertreatmentDieselParticulateFilter(DPF)......................................................165

AftertreatmentControlModule(ACM).................................................................166

ExhaustAftertreatmentSystem............................................................................166

DriverWarningsandOnBoardDiagnostics(OBD).............................................172

OnBoardDiagnostics(OBD)................................................................................172

InstrumentCluster..................................................................................................173

MalfunctionIndicatorLamp(MIL).......................................................................174

AftertreatmentDEFTankLevel-DriverWarning&Inducement........................175

AftertreatmentDEFQuality-DriverWarning&Inducement..............................176

MisllingDieselorAftertreatmentDEFTanks.....................................................177

SCRTampering-DriverWarning&Inducement.................................................178

WarrantyandMaintenance....................................................................................179

ExhaustAftertreatmentSystemMaintenance........................................................179

EngineMaintenanceIntervals................................................................................179

MAINTENANCEANDLUBRICATION..................................................................180

MAINTENANCEINTRODUCTION.......................................................................180

TURBOCHARGER...................................................................................................181

CLEANINGYOURVEHICLE.................................................................................182

ExteriorWashing...................................................................................................182

CabandHood........................................................................................................184

Chassis...................................................................................................................184

CabInterior............................................................................................................184

Waxing...................................................................................................................185

Polishing................................................................................................................185

WinterW arnings....................................................................................................185

TOWING...................................................................................................................186

ENGINEOILLEVELCHECK.................................................................................188

PowerSteeringReservoir......................................................................................189

FUELTANK..............................................................................................................190

FuelTankCap........................................................................................................190

FUELING..................................................................................................................191

BioDiesel................................................................................................................192

B5ApprovalForMACKUS2010CertiedProducts..........................................192

COOLINGSYSTEM.................................................................................................194

CoolantLevelCheck..............................................................................................194

DrainingtheCoolingSystem.................................................................................195

RellingtheCoolingSystem.................................................................................195

ProtectingtheCoolingSystem..............................................................................196

CoolingSystemMaintenance................................................................................197

AccessoryDriveBeltRouting...............................................................................198

HEADLIGHTS..........................................................................................................199

BulbReplacement..................................................................................................199

WHEELS...................................................................................................................199

WheelInspection...................................................................................................199

Tires.......................................................................................................................200

BATTERY..................................................................................................................203

Jump-StartingEngine.............................................................................................203

ELECTRICAL...........................................................................................................205

CircuitBreakerandRelayPanels..........................................................................205

ElectricalGrease....................................................................................................209

CircuitProtectionCharts........................................................................................210

METRICCONVERSIONS.........................................................................................212

METRICCONVERSIONS.......................................................................................212

SafetyInformation

IMPORTANT:Beforedrivingthis vehicle,becertainthatyouhaveread andthatyoufullyunderstandeachand everystepofthedrivingandhandling informationinthismanual.Becertain thatyoufullyunderstandandfollowall safetywarnings.

ITISIMPORT ANTTHA TTHE FOLLOWINGINFORMA TIONBE READ,UNDERSTOODANDALW AYS FOLLOWED.

Thefollowingtypesofadvisoriesareused throughoutthismanual:

DANGER

Dangerindicatesanunsafepracticethat couldresultinseriouspersonalinjury ordeath.Adangeradvisorybanneris inwhitetypeonablackbackground withablackborder.

WARNING

Warningindicatesanunsafepractice thatcouldresultinpersonalinjury.A warningadvisorybannerisinblack typeonagraybackgroundwithablack border.

CAUTION

Cautionindicatesanunsafepracticethat couldresultindamagetotheproduct. Acautionadvisoryisinblacktypeona

whitebackgroundwithablackborder.

Note:Noteindicatesaprocedure,practice,

orconditionthatmustbefollowedinorder forthevehicleorcomponenttofunction inthemannerintended.

INTRODUCTION1

TOTHEOWNER

InAppreciation

ThankyouforbuyingaMackK®vehicle.Withpropercareandmaintenance, yournewMack®T erraPro™LEUmodelwillhelpyougainacompetitiveedge withitsfuel-efcientdrivetraincombinations,lowmaintenance,extended serviceintervalsand,eventually ,goodresalevalue.

TheMack®TerraPro™LEUmodelisavailableforawiderangeof applications.Becauseofthisversatility ,drivetrainsandcomponentsvaryand operatinginstructionsmaydifferfromonemodeltoanother.Whileevery efforthasbeenmadetocoverallcurrentarrangements,donothesitateto consultyourMACKdistributorifaquestionarises.Honest,personalservice isstandardwitheveryMACKsale.

CAUTION

MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.

We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack® TerraPro™LEUmodel,andthatyouseemanyyearsoftrouble-freedriving.

Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations applicableatthetimeofmanufacture.

2INTRODUCTION

AboutThisHandbook

ThishandbookisreferredtoastheMack®T erraPro™LEUSeriesOperator’s Handbook.ItcoversallMack®T erraPro™LEUmodels.Itsidentication

numberis21394654.Keepthishandbookwiththevehicleatalltimesto ensurethateachownerand/oroperatorwillhaveaccesstoallpertinent informationrelatingtotheoperationandhandlingofthisvehicle.

Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation concerningthedailyoperationofthisvehicle.Pleasereaditthoroughly; payparticularattentiontoadvisorylabelsthathavebeenincludedtodraw attentiontoimportantissuesofoperatorsafetyandoverallperformance.

Informationandillustrationsinthishandbookarebasedonthelatest productionusageatthetimeofprintingandaresubjecttochangewithout priornotice.

Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual beginningwith“MAINTENANCEINTRODUCTION”,page180.Forfurther information,refertotheMaintenanceandLubricationManual(21394653).Other importantinformationcanbefoundintheEmissionControlSystemsforMACK DieselEngineManual(21351488).

INTRODUCTION3

THEVEHICLE

BasicConguration

TheMack®T erraPro™LEUmodelhasalow-entry ,cab-forward-style operatorscompartment.One-stepentryanddualsteering/braking arrangementsmakeitaverypopularandpracticalvehicleforrefuse managementcompanies.

VehicleManagementandControlSystem (V-MAC®)

TheVehicleManagementandControlSystem(V-MAC)isanelectronic controlsystemthatmanagesengineandvehiclefunctions.Inaddition,the DataMax™portionofV-MACmonitorsandstoresavarietyofinformation(i.e., maintenanceschedules,overspeedlogs,faulttables,tripsummaries).

ForacompletedescriptionoftheV-MACIVsystem,refertotheapplicable V-MAC®Operator’sGuide,whichissuppliedwiththevehicle.

Additionalinformationconcerningservice,diagnostics,programmingand vendorequipmentinterfaceapplicationisavailablefromtheMackTrucks,Inc. ServicePublicationsDepartment.ContactyourlocalMACKdealerfordetails.

WARNING

NevercutintotheV-MACsystemwireharnesstopoweradditionalequipment.If suchequipmentistobeinstalled,contactyourMACKdealerforassistance.

4INTRODUCTION

COMPONENTIDENTIFICATION

Locatethefollowingserialnumbersandwritethemintheboxesprovided nexttoeachillustration.

VINLocations

TheV ehicleIdenticationNumber(VIN)isdisplayedintwolocations(aframe railstampingandalabel).The17-digitVINmustbeidenticalinbothlocations.

TheVINframestampingislocatedontherightoutsideframerailandthe leftinsideframerail.

C0029554

TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.

C0028941

INTRODUCTION5

EngineIdentication

OntheMACKMPengines,theengineserialnumberisstampedontheleft sideoftheengineblock,belowtheinletmanifold.

C0028943

6INTRODUCTION

EngineInformationPlate

IncompliancewithFederalandCaliforniaemissionrequirements,an engineinformationlabelisafxedtoallMACKdieselengines.Thislabel, whichislocatedonthecylinderheadcoveratthefrontoftheengine,gives basicengineidenticationinformation(enginemodel,serialnumber,etc.), advertisedhorsepoweratratedspeed,emissionsregulationstowhichthe engineconformsandinletandexhaustvalvelashsettings.Examplesofthe 49stateEPAapproved,and50stateEPAandCaliforniaapprovedengine identicationlabelsaregivenbelow.

W2040455

EngineIdenticationLabel-49StateEPAApprovedEngine

withoutCalifornia"CleanIdle"

EngineIdenticationLabel-50StateEPAApprovedEngine

withCalifornia"CleanIdle"

W2040456

INTRODUCTION7

CleanIdleEngines

TheCaliforniaAirResourcesBoard(ARB)requiresthat2008andlatermodel yearvehiclesbeequippedwithengineshavingtamper-resistantsoftware whichlimitsthetimeatwhichtheenginecanidleatspeedsabovelowidle (550–700rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idle timewillbelimitedtoveminutes,afterwhichtheenginewillrevertback tolowidle.V ehiclesequippedwithaCleanIdleengineareidentiedbya labelwhichisafxedtothelowerportionofthedriver’ssidedooroncab-over models(LEU).

CleanIdleEngineLabel

W2056289

8INTRODUCTION

TransmissionIdentication

TheAllisonRDSandHStransmissionidenticationplateislocatedonthe rearrightsideofthemaincase,nearthelowerend.

C0029555

TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside ofthehousing.

C0028950

TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe axlehousingtowardthecarrier.

C0028951

INTRODUCTION9

TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft sideoftheforwardcarrier,andthetopoftherearcarrier.

C0028952

TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof therearaxlehousing,nexttothecarrier.

C0028953

TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof theforwardcarrier,andthetopoftherearcarrier.

C0028954

10INTRODUCTION

WARRANTYINFORMATION

ThischassisisequippedwithaUS’10emissioncompliantengineandan exhaustaftertreatmentsystem(DieselParticulateFilter).UseofUltraLow SulfurDiesel(ULSD)fuelandEO-OPremiumPlus(orVDS-4)specication highperformancedieselengineoilisrequiredinthisvehicle.

Note:Useofimproperorunapprovedfuelorengineoilwillvoidtheengineand aftertreatmentsystemwarranty.

AirBrakeSystem

TheMACKStandardVehicleWarrantyappliestotheairbrakesystem,as setforthintheWarranty,butonlyiftheairbrakesystemhasnotbeen subjectedtounauthorizedadditions,deletionsormodications.Ifanysuch unauthorizedadditions,deletionsormodicationsareperformed,Mack Trucks,Inc.disclaimsanyandallliabilityforanylossordamagearisingoutof amalfunctionoftheairbrakesystem.

Theairbrakesystemwasdesignedandbuilttoconformtoallapplicable federalmotorvehiclesafetystandardsineffectatthetimeofmanufacture.

Tractorairsystemsaredesignedforoperationasatractoronly,andtruckair systemsaredesignedtobeoperatedasatruckonly .Ifatractorisgoingtobe convertedforoperationasatruck,theairbrakesystemmustberecongured tothatofatruck.Conversely,ifatruckisgoingtobeconvertedforoperation asatractor,theairbrakesystemmustbereconguredtothatofatractor. ConsultyourlocalMACKdistributorforadditionalinformation.

Ifanyunauthorizedadditions,deletionsormodicationsaremadetoany portionoftheairbrakesystemwhichisrequiredbyFederalMotorVehicle SafetyStandards,MackTrucks,Inc.makesnorepresentationastoconformity withtheStandards.

Forcompletewarrantyinformation,refertothePedigreedProtectionPlan providedwitheachvehicle.

ENGINEGASEOUSEMISSIONCONTROL SYSTEMS

WARRANTYMAINTENANCE

Note:Foremissioncontrolsystems informationonenginesotherthanMACK, refertotheenginevendor’spublication

INTRODUCTION11

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY

MackTrucks,Inc.warrantstheEmission ControlSystemsoneachnewMack dieselengineinanewMackTruckto complywithallUnitedStatesFederal andCanadianemissionsregulations applicableatthetimeofmanufactureof theengine,andtobefreefromdefects inmaterialandworkmanshipunder normaluseandserviceupto60months, or160934km(100,000miles),which everoccursrst,providedthatallMack Trucks,Inc.maintenancerequirements arefollowedasdescribedinthismanual. Allwarrantyperiodsarecalculatedfrom thedate-in-serviceofthenewvehicle.

Therepairorreplacementofdefective partswillbemadewithoutchargefor thecostofpartsandifrepairsaremade atanauthorizedMackTrucks,Inc. dealership,therewillbenochargefor labor.MackTrucks,Inc.’sobligation underthiswarrantyislimitedtotherepair orreplacement,atMackTrucks,Inc.’s option,ofanypart(s)oftheEmission ControlSystemsofsuchengineand/or vehiclefoundtobedefectiveupon examinationbyMackTrucks,Inc.and providedthatsuchpart(s)werereturnedto MackTrucks,Inc.oritsnearestauthorized Dealerwithinareasonableperiodoftime.

QualicationsandLimitations:

Note:NotcoveredbytheEmissions ControlSystemsW arranty:

•Malfunctionscausedbymisuse,

improperadjustments,modication, alteration,tampering,disconnection, improperorinadequatemaintenance anduseofimproperdieselfuelorDEF .

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

THISW ARRANTYISEXPRESSL YINLIEUOFALLOTHERW ARRANTIES ANDREPRESENTATIONSORCONDITIONS,STA TUTORYOR OTHERWISE,EXPRESSEDORIMPLIEDINCLUDING,BUTNOTLIMITED TO,IMPLIEDW ARRANTYOFMERCHANTABILITYORFITNESSFORA PARTICULARPURPOSE.

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheFederalcodeofemissionregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACHoses

3EngineControlModule(ECM)

4Injectors

•CACPipes(Airinletto/fromCAC)

12INTRODUCTION

5EngineandVehicleWireharness(

repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRValveandEGRV alveControl

9EGRPipes-EngineExhaustManifold

toEGRCooler

10EGRPipes-EGRCoolertoInlet

Manifold

11CrankcaseBreather

12CrankcaseSeparator

13CrankcaseTubingandHosesbefore

Separator

14AftertreatmentWiringHarness

15AftertreatmentControlModule(ACM)

16AftertreatmentDieselParticulateFilter

(DPF)Assembly

A.AftertreatmentDPFAssembly withAftertreatmentDieselOxidation Catalyst(DOC)

•AftertreatmentDoser

•DiffuserPipe(AftertreatmentFuel

DoserMounting)

•FuellinestoAftertreatmentFuel

Doser

•AftertreatmentFuelShutoffV alve

•AftertreatmentFuelPressureSensor

•DischargeRecirculationValve

(DRV)(HeatMode)

•DischargeRecirculationValve

(DRV)Solenoid

•EngineTurbochargerCompressor

BypassActuator(HeatMode)

•EngineTurbochargerCompressor

BypassActuatorSolenoid

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFCombustion

AirControlV alve

•AftertreatmentDPFCombustion

AirV alve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

INTRODUCTION13

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AA T)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFTank

Heater/Sender

ENGINEGASEOUSEMISSIONSCONTROL SYSTEMWARRANTY

•AftertreatmentDEFTankHeater

•AftertreatmentDEFT ankHeater

Valve

•AftertreatmentDEFTank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

19.InstrumentCluster(Repairof microprocessor,OBDMIL,RealTime Clock,AftertreatmentDEFTankGauge and,AftertreatmentDEFTankLowLevel Indicator)

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

Theemissionwarrantyforthediesel particulatelter(DPF)andSCRSystem coversdefectsinworkmanshiponly. Normalmaintenance,suchascleaning ashfromthelteratregularmaintenance intervalsandcleaningtheaftertreatment fuelinjectoronDieseloxidationcatalyst (DOC)DPFsystems,isnotcoveredby theemissionwarranty.WiththeThermal regeneratorDPFsystem,cleaningthe ignitionelectrodesandfuelinjection nozzleattheregularmaintenanceintervals

isconsiderednormalmaintenanceandnot coveredbytheemissionwarranty .

Note:Inresponsetocustomerrequests, MackTrucks,Inc.maybuildvehicleswith enginessuppliedbyothermanufacturers. Inthesecases,eachenginemanufacturer throughitsserviceorganization,is responsibleforemissioncontrolsystems warrantyonallpartsoftheengine assembly,asfurnished.

14INTRODUCTION

FEDERALEMISSIONREQUIREMENTS

Thissectioncoverstherequirementofthe UnitedStatesCleanAirActwhichstates: “Themanufacturershallfurnishwith eachnewmotorvehicleormotorvehicle enginesuchwritteninstructionsforthe maintenanceanduseofthevehicleor enginebytheultimatepurchaserasmay

TAMPERINGWITHGASEOUSEMISSIONCONTROLSYSTEMS PROHIBITED

TheFederalCleanAirActprohibitsthe removalorrenderinginoperativeofany deviceorelementofdesigninstalledonor inamotorvehicleormotorvehicleengine incompliancewithFederalEmission Regulationsby:

1Anypersonpriortoitssaleanddelivery

totheultimatepurchaser,or

2Anymanufacturerordistributorafter

itssaleanddeliverytotheultimate purchaser,or

3Anypersonengagedinthebusinessof

repairing,servicing,selling,leasing,or

bereasonableandnecessarytoassurethe properfunctioningofemissioncontrol devicesandsystems.”Thissectionalso coverstherequirementsoftheemissions regulationspromulgatedundertheMotor VehicleSafetyActinCanada.

4Anypersonwhooperatesaeetof

Note:Forspecicsoftheprohibited vehicle/enginemodicationsreferto theMackTrucks,Inc.BodyBuilders documentation.

tradingmotorvehiclesormotorvehicle enginesfollowingitssaleanddelivery totheultimatepurchaser,or

motorvehiclesfollowingitssaleand deliverytotheultimatepurchaser.

EMISSIONCONTROLSYSTEMSWARRANTY— CALIFORNIA

TheCaliforniaAirResourcesBoardand MackTrucks,Inc.arepleasedtoexplain theCaliforniaemissioncontrolsystem warrantyonyournewmotorvehicle engine.InCalifornia,newmotorvehicle enginesmustbedesigned,builtand equippedtomeettheState’sstringent anti-smogstandards.MackTrucks,Inc. mustwarranttheemissioncontrolsystem onyourenginefortheperiodoftimelisted belowprovidedtherehasbeennoabuse, neglect,orimpropermaintenanceofyour engine. Youremissioncontrolsystemmay includepartssuchasthefuel-injection

system,turbochargerassembly,electronic controlmoduleandotheremission-related assemblies. Whereawarrantableconditionexists, MackTrucks,Inc.willrepairyourengine atnocosttoyouincludingdiagnosis, parts,andlabor.

MANUFACTURER’SW ARRANTY COVERAGE:

Ifanemission-relatedpartofyourengine isdefective,thepartwillberepairedor replacedbyMackTrucks,Inc.Thisis youremissioncontrolsystemDEFECTS WARRANTY .

OWNER’SWARRANTYRESPONSIBILITIES:

INTRODUCTION15

Asthemotorvehicleengineowner,you areresponsiblefortheperformanceof therequiredmaintenancelistedinthis manual.MackTrucks,Inc.recommends thatyouretainallreceiptscovering maintenanceofyourvehicle,butMack Trucks,Inc.cannotdenywarrantysolely forthelackofreceiptsorforyourfailure toensuretheperformanceofallscheduled maintenancelistedinothermanualswhich weresuppliedwithyourvehicle. Youareresponsibleforpresenting yourmotorvehicleenginetoaMACK dealerassoonasaproblemexists.The warrantyrepairsshouldbecompleted inareasonableamountoftime,notto exceed30days.Asthemotorvehicle engineowner,youshouldalsobeaware thatMackTrucks,Inc.maydenyyou warrantycoverageifyourvehicleora parthasfailedduetoabuse,neglect, impropermaintenance,orunapproved modications. Ifyouhaveanyquestionsregarding yourwarrantyrightsandresponsibilities, youshouldcontacttheMackTrucks, Inc.WarrantyActivitiesP .O.Box26259, Greensboro,NC27402,ortheCalifornia AirResourcesBoardat9480Telstar Avenue,ElMonte,California91731.

(Applicableonlytovehiclesand/or enginescertiedforsaleandregistered

intheStateofCalifornia)MackTrucks,

Inc.warrantstheEmissionControl SystemsoneachnewMACKdiesel engineinanewMACKtrucktocomply withallStateofCaliforniaemissions regulationsapplicableatthetimeof manufactureoftheengine,andtobefree fromdefectsinmaterialandworkmanship undernormaluseandserviceupto 60months,or100,000miles,or3,000 engineoperatinghours,whicheveroccurs rst,providedthatallMackTrucks, Inc.maintenancerequirementsare followedasdescribedinthismanual.All warrantyperiodsarecalculatedfromthe date-in-serviceofthenewvehicle.The repairorreplacementofdefectiveparts willbemadewithoutchargeforthecost ofpartsand,ifrepairsaremadeatan authorizedMackTrucks,Inc.dealership, therewillbenochargeforlabor. MackTrucks,Inc.’sobligationunder thiswarrantyislimitedtotherepair orreplacement,atMackTrucks,Inc.’s option,ofanypart(s)ofEmissionControl Systemsofsuchengineand/orvehicle foundtobedefectiveuponexaminationby MackTrucks,Inc.andprovidedthatsuch part(s)werereturnedtoMackTrucks,Inc. oritsnearestauthorizedDealerwithina reasonableperiodoftime.

QualicationsandLimitations:

NotcoveredbytheEmissionsControl SystemsW arranty:

•Malfunctionscausedbymisuse,

improperadjustments,modication, alteration,tampering,disconnection, improperorinadequatemaintenance anduseofimproperdieselfuelorDEF .

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

16INTRODUCTION

EmissionsControlSystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol systemwarrantypolicyasrequiredbytheCaliforniacodeofregulations.

1TurbochargerAssembly

•VGTActuator

2ChargeAirCooler

•CACPipes(Airinletto/fromCAC)

•CACHoses

3EngineControlModule(ECM)

4Injectors

5EngineandV ehicleWireharness

(repairtocircuitsrelatedtoEmissions WarrantableComponents)

6ExhaustGasRecirculation(EGR)

Mixer

7EGRCooler

8EGRValveandEGRV alveControl

9EGRPipes-EngineExhaustManifold

toEGRCooler

10EGRPipes-EGRCoolertoInlet

Manifold

11CrankcaseBreather

12CrankcaseSeparator

13CrankcaseTubingandHosesbefore

Separator

14AftertreatmentWiringHarness

15AftertreatmentControlModule(ACM)

16AftertreatmentDieselParticulateFilter

(DPF)Assembly

A.AftertreatmentDPFAssembly withAftertreatmentDieselOxidation Catalyst(DOC)

•AftertreatmentDoser

•DiffuserPipe(AftertreatmentFuel

DoserMounting)

•FuellinestoAftertreatmentFuel

Doser

•AftertreatmentFuelShutoffV alve

•AftertreatmentFuelPressureSensor

•EngineTurbochargerCompressor

BypassActuator(HeatMode)

•EngineTurbochargerCompressor

BypassActuatorSolenoid

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

•AftertreamentDoserAirSupply

Regulator(ifapplicable),Supply Lines,andFittings

B.ThermalRegenerationUnit(TRU)

•AftertreatmentDPFAirShutoff

Valve

•AftertreatmentDPFCombustion

AirV alve

•AftertreatmentDPFAtomization

Module

•AftertreatmentDPFIgnitionCoil

INTRODUCTION17

•AftertreatmentDPFFuelControl

Valve

•AftertreatmentDPFIgnition

Electrode

•Nozzle

•EngineExhaustGasTemperature

(EGT)Sensor

•AftertreatmentDPFIntake

TemperatureSensor

•AftertreatmentDPFOutlet

TemperatureSensor

•AftertreatmentDPFSparkAssist

FlameTemperatureSensor

•AftertreatmentDPFDifferential

PressureSensor

17Sensors:

•CrankshaftPosition(CKP)

•CamshaftPosition(CMP)

•EngineCoolantTemperature(ECT)

•IntakeManifoldAirTemperature

•IntakeManifoldPressure(IMP)

•EGRTemperature

•AftertreatmentOutletNOx

•AftertreatmentIntakeNOx

•EGRDifferentialPressure

•AmbientAirTemperature(AA T)

18SCR

•AftertreatmentSelectiveCatalytic

Reduction(SCR)Catalyst

•AftertreatmentDieselExhaustFluid

(DEF)Pump

•AftertreatmentDEFDosing

AbsolutePressureSensor

•AftertreatmentDEFReturn

Valve

•AftertreatmentDEFDosingV alve

•AftertreatmentDEFTank

Heater/Sender

•AftertreatmentDEFTankHeater

•AftertreatmentDEFT ankHeater

Valve

•AftertreatmentDEFTank

TemperatureSensor

•AftertreatmentDEFLevelSensor

•AftertreatmentDEFHeatedLines

19.InstrumentCluster(Repairof microprocessor,OBDMIL,RealTime Clock,AftertreatmentDEFTankGauge and,AftertreatmentDEFTankLowLevel Indicator)

20.ExhaustGasPiping(from TurbochargertoAftertreatmentSystem)

21.DataLinkConnector(DLC)

18INTRODUCTION

ENGINEGASEOUSEMISSIONCONTROLSYSTEMS WARRANTY—Continued

CAUTION

Anyunauthorizedadjustmentstothe emissioncontrolcomponentscancause severedamagetotheengine.

establishment,orbytheowner,usingany replacementpart,withinthelimitations ofparagraphs3and4inthissection.An emergencyconditionexistsunderthis sectionif,after30days,repairshave notbeencompletedorpartsarenotyet available.MACKwillreimbursethe ownerforsuchrepairsthatarecovered underthiswarranty ,includingdiagnosis, nottoexceedMACK’ssuggestedretail priceforpartsreplacedandlaborcharges basedonMACK’srecommendedtime allowanceandgeographicallyappropriate hourlylaborrate.Replacedpartsandpaid invoicesmustbepresentedataMACK facilityasaconditionofreimbursementfor emergencyrepairsperformedelsewhere.

CAUTION

Intheeventthatdamageresultsfrom unauthorizedadjustmentstoany emissioncontrolsystemcomponents, asevidencedbysettingsotherthanas specied,orbrokenfastenerseals,the costofrepairingsuchdamageWILL NOTBECOVEREDunderwarranty

1.RepairsbyMACKDealers,

Sub-DealersandServiceDealers

RepairscoveredbytheCalifornia EmissionControlSystemsW arrantywill beperformedbyanyauthorizedMACK repairfacilityathisplaceofbusinesswith nochargeforpartsandlabor(including diagnosis),usingMACKpartsforanypart oftheemissioncontrolsystemscovered bythiswarrantyandfounddefective.

2.InanEmergency Inanemergency,whereanauthorized MACKfacilityisnotavailable,repairs maybeperformedatanyavailableservice

3.RepairsbyNon-MACKFacilities Ownersmayelecttohavemaintenance, replacement,orrepairofemissioncontrol systemsperformedbyanyrepairfacility, andmayelecttousepartsotherthan MACKpartswithoutinvalidatingthe warrantyonothercomponents,butthe costofsuchserviceorpartswillnotbe coveredbyMACKunderitswarranty.

4.UseofNon-MACKParts Useofreplacementpartswhicharenotthe equivalentofMACKpartsmayimpairthe effectivenessofemissioncontrolsystems. IfotherthanMACKpartsareused,the

INTRODUCTION19

ownershouldobtainassurancesthatsuch partsarewarrantedbytheirmanufacturer tobetheequivalentofMACKparts inperformanceanddurability.MACK assumesnoliabilityunderthiswarranty withrespecttopartsotherthanMACK parts;however,theuseofnon-MACK partsdoesnotinvalidatethewarrantyon othercomponentsunlessnon-MACKparts causedamagetowarrantedparts.

5.MaintenanceandMaintenance

Records

Thevehicleownerisresponsibleforthe performanceofallrequiredmaintenance speciedinthismanual.MACKwillnot denyawarrantyclaimsolelybecausethere isnorecordofmaintenance;however, MACKmaydenyawarrantyclaimif failuretoperformrequiredmaintenance resultsinthefailureofawarrantedpart. Receiptsorotherrecordscoveringthe performanceofscheduledmaintenance shouldberetainedtoanswerquestions thatmayariseconcerningmaintenance. Maintenancerecordsshouldbetransferred tosubsequentownersifthevehicleissold.

6.ItemsNotCoveredbytheEmission

ControlSystemsWarranty

•Malfunctionscausedbymisuse,

improperadjustments,modication, alteration,tampering,disconnection, improperorinadequatemaintenance anduseofimproperdieselfuel.

•Damageresultingfromaccident,acts

ofnatureorothereventsbeyondthe controlofMackTrucks,Inc.

•Inconvenience,lossofuseofthe

vehicle,commerciallossofany kindincluding,butnotlimitedto, consequentialorincidentaldamages.

•Anyvehicleinwhichtheodometer

hasbeenalteredordamagedsothat mileagecannotbereadilydetermined.

7.CustomerAssistance MACKwishestoassurethattheCalifornia EmissionControlSystemsWarrantyis properlyadministered.Intheeventthat ownersdonotreceivethewarrantyservice towhichtheybelievetheyareentitled undertheCaliforniaEmissionControl SystemsW arranty ,theyshouldcontact thenearestMACKRegionalOfcefor assistance.Theaddressandtelephone numberforeachRegionalOfceare intheMACKDirectoryofSales,Parts andServiceCenters.Ownersinneed ofadditionalassistanceorinformation concerningtheCaliforniaEmission ControlSystemsW arrantymayalso contact:

MackTrucks,Inc.

WarrantyActivities

P.O.Box26259

Greensboro,NC27402

20INTRODUCTION

SERVICELITERATURE

TheMACKServicePublicationsdepartmentoffersavarietyofserviceliterature (includingindividualservicemanuals)thatcanbeorderedthroughanyMACK dealerorontheMackTrucks,Inc.websiteatwww.macktrucks.com.

Note:MackTrucks,Inc.wouldliketoemphasizetheimportanceofproperservice andmaintenanceprocedures.Service,repairandreplacementsmustbeperformedby certied,licensedmechanicsinaccordancewithMACKstandards.

MACKClass8–ComponentsServiceManual

Thismulti-bindersetcontainsserviceinformationcoveringallMACK components(i.e.,engines,transmissions,frontandrearaxles,cabs,fuel systems,electricalsystems).

Note:Ifyourvehiclecontainsanumberofnon-MACK(vendor)components,the

Class8–CustomCollatedServiceManualmightbemoreappropriate.

MACKClass8–CustomCollatedServiceManual onCD

INTRODUCTION21

CUSTOMERSERVICE

Call1-800-866-1177forMACKOneCall™

TheOneCallcustomersupportsystemisatoll-freenationwidehotlinethat operates24hoursaday,sevendaysaweek,includingholidays.Ifyoubreak downontheroad,simplycall1-800-866-1 177.Thereisastaffoftrained, experiencedtechniciansreadytohelp.Theycanhelptroubleshootaproblem togetyoubackontheroad,arrangetosendroadsideassistanceorarrange fortowingtothenearestMACKdealership.

OneCallprovidespersonalizedservice.Thepersonwhoinitiallytakesyour callwillbethesamepersonwhoseesthatyoursituationisresolvedquickly andtoyoursatisfaction.Ifafollow-upcallisnecessary ,thesamefamiliar voicewillbeontheotherendoftheline.

OneCalltechnicianscanalsohelpyouplanaheadtokeepyouroperation runningefcientlybyschedulingroutinemaintenanceandlubricationservice, orbylocatingthenearestMACKdealership.

QuestionsandComplaints

Yoursatisfactionisourmostimportantconcern.

Ifquestionsorcomplaintsarise,rstdiscussthematterwiththeservice managerattheMACKfacilityinvolved.Ifyouarenotsatisedwiththe servicemanager’sresponse,contactthebranchmanager,principalorgeneral managerofthedistributorship.Ifassistanceisrequiredataservicedealer, contacttheowneroftheestablishment.

If,foranyreason,youneedfurtherassistanceafterdealingwiththepersonnel ataMACKsubsidiaryordistributor,contacttheregionalservicemanagerat thenearestMACKregionalserviceofce.Theregionalservicemanagerhas theresponsibilityandtheauthoritytorecommendactioninmostcasesand (withtheaidofrelevantdistrictservicepersonnel)willmakeeveryeffortto conductafairreviewofthesituation.

22INTRODUCTION

Addresses

Theaddresses,telephoneandfaxnumbersoftheMackTrucks,Inc.regional ofcesare:

UnitedStates

NortheastRegion–7900NationalServiceRoad.,Mail:P .O.Box26259, GreensboroNC27402,TEL:(336)291-9001

SoutheastRegion–6768SouthlakeParkway,Morrow,GA30260,TEL: (770)960-0511,FAX:(770)960-0593

CentralRegion–900S.FrontageRd.,Suite100,Woodridge,IL60517,TEL: (630)910-3330,FAX:(630)910-3331

SouthwesternandWesternRegions–5605N.MacArthurBlvd.,#550, Mail:P .O.Box165408,Irving,TX75016-5408,TEL:(972)518-1614,FAX: (972)550-0389

Canada

ExecutiveOfce–MackCanada,Inc.,5600ACancrossCourt,Mississauga, ONL5R3E9,TEL:(905)366-3400,FAX:(905)366-0165

Australia

MackTrucksAustraliaPty .Ltd.,CNRArchereldandBoundaryRoads,Mail: P .O.Box364,Richlands,QLD4077,Australia,TEL:61-7-3853-3333,FAX: 61-7-3853-3392

International

7900NationalServiceRoad.,Mail:P .O.Box26259,GreensboroNC27402, TEL:(336)291-9001

AdditionalAssistance

Ifadditionalassistanceisrequired,MackTrucks,Inc.maintainsaCustomer ServiceDepartment(staffedbyexperiencedpersonnel)toaidcustomerswho needinformationorassistancenotprovidedatthelocalorregionallevel.

TheCustomerServiceDepartmentphonenumberis(610)709-3961.

WhencontactingtheregionalserviceofcesorCustomerServiceDepartment, providethefollowinginformation:

•VehicleIdenticationNumber(VIN)—This17-digitnumberistypicallylocated

onalabelonthedriver-sidedoorlatchpostandbehindthefrontaxleonthe right,frontframerail.

INTRODUCTION23

•Modelandyearofthevehicle

•Datethatthevehiclewaspurchasedandputintoservice

•Date(s)andmileageofrepair(s)

•Dealerthatsoldand/orservicedthevehicle

•Descriptionofunresolvedservicecomplaintorinquiry

•Summaryofactiontakentodate(bythedealerandtheregionalserviceofce)

•Namesofindividuals(ifknown)contactedatthedealerandtheMackTrucks,Inc.

regionalserviceofce.

24INTRODUCTION

REPORTINGSAFETYDEFECTS

UnitedStates

Ifyoubelievethatyourvehiclehasadefectwhichcouldcauseacrash,injury ordeath,youshouldimmediatelyinformtheNationalHighwayTrafcSafety Administration(NHTSA),inadditiontonotifyingMackTrucks,Inc.

IfNHTSAreceivessimilarcomplaints,itmayopenaninvestigationandifit ndsthatasafetydefectexistsinagroupofvehicles,itmayorderarecalland remedycampaign.However,NHTSAcannotbecomeinvolvedinindividual problemsbetweenyou,yourdistributor,orMackTrucks,Inc.

TocontactNHTSA,eithercalltheU.S.Government’sVehicleSafety Hotlinetoll-freeat1-888-327-4236(TTY:1-800-424-9153);goto

ttp://www.NHTSA.gov;orwriteto:Administrator,NationalHighwayTrafc

h SafetyAdministration,400SeventhStreet,S.W.,Washington,DC20590. Youcanalsoobtainotherinformationaboutmotorvehiclesafetyfromthe VehicleSafetyHotline.

Canada

Canadiancustomerswhowishtoreportasafety-relateddefecttoTransport Canada—DefectInvestigationsandRecalls,maytelephonethetollfree hotlineat1-800-333-0510,orcontactTransportCanadabymailatTransport Canada,ASF AD,PlacedeVilleT owerC,330SparksStreet,OttawaONK1A 0N5.Foradditionalroadsafetyinformation,pleasevisittheRoadSafety websiteathttp://www.tc.gc.ca/roadsafety/menu.htm.

Mexico

VolvoTrucksdeMexico,S.A.deC.V .shouldbeinformedimmediatelyifyou believethevehiclehasadefectthatcouldcauseavehicleaccident,injuryor death.ContactVolvoTrucksdeMexicobycalling011-52-55-50-81-68-50 orbywritingto:VolvoTrucksdeMexico,S.A.deC.V.,Prol.Paseodela Reforma600,1er.Piso—121,Col.SantaFePenaBlanca,C.P.01210, Mexico,D.F .WithinMexico,call01(800)9094900.

INTRODUCTION25

EVENTDATARECORDINGDEVICES

YourMackvehicleisequippedwithadevicegenerallyreferredtoasan"event datarecorder"or"EDR."Pleasenotethatwhiletheterm"eventdatarecorder" istypicallyusedthroughoutthemotorvehicleindustry,noteveryEDRisthe same;i.e.,theydonotallrecordthesamedataelements.TheEDRonyour MACKvehiclerecordsvehiclespeed,enginerpm,timeanddate,plusa varietyofpedalandswitchpositions,bothbeforeandafteran"event."Sudden vehicledecelerationortheoccurrenceofcertainothervehicleoperational characteristicswilldene(trigger)an"event."

OptionalequipmentavailableforyourMACKvehicle,suchastheEaton® VORAD®CollisionWarningSystem,mayalsoprovideeventdatarecording features.

IfyouhaveaquestionaboutyourEDR,pleasecontactyourMACKdealeror regionalserviceofce.

26SAFETYINFORMATION

SAFETYST ATEMENT

MackTrucks,Inc.cannotanticipateeverypossibleoccurrencewhichmay involveapotentialhazard.Anaccidentcanbeavoidedbyrecognizing potentiallyhazardoussituationsbeforeadangeroussituationoccurs. Correctlyperformedserviceproceduresarecriticalfortechniciansafetyand safe,reliableoperationofthevehicle.

DANGER

Donotoperatetheengineinanenclosedarea.Allinternalcombustionengines giveoffvariousfumesandgaseswhilerunning.Inhalationofexhaustfumescan causedeath.

DANGER

Donotsitinaparkedvehicleforanyextendedamountoftimewiththeengine runningifthereareleaksintheexhaustsystem.Exhaustfumescouldleakintothe cabareaanddeathcanresult.Onaregularbasisinspecttheexhaustsystemfor leaksandrepairanyleakage.

DANGER

Driverattitudeisthemostimportantpartofanyeffectivevehiclesafetysystem. MackTrucks,Inc.stronglyencouragesalldriversandpassengerstousetheirseat belts,drivedefensively,remainalertandrespectthespeedlimits.Manyaccidents canalsobeavoidedthroughregularvehiclemaintenance.

DANGER

Engine-drivencomponentssuchasPowerTake-Off(PTO)units,fansandfanbelts, driveshaftsandotherrelatedrotatingassemblies,canbeverydangerous.Donot serviceengine-drivencomponentsunlesstheengineisshutdown.Alwayskeep bodypartsandlooseclothingoutofrangeofthesepowerfulcomponentstoprevent seriouspersonalinjury .BeawareofPTOengagementornonengagementstatus. AlwaysdisengagethePTOwhennotinuse.

SAFETYINFORMATION27

WARNING

Certaineverydayproceduressuchaswashingthevehicleandcleaningthe windshieldcanalsobehazardousbecauseofthevehicle’ sheight.MackTrucks, Inc.doesNOTrecommendclimbinguponthevehicletoperformtheseoperations. Instead,standonthegroundandusebrushesandsqueegeesmountedonextension poles.Whenbetteraccessisnecessary(forinstance,whenwashingthecabroof), usesturdyladdersheldinplacebysomeoneontheground.

WARNING

Securelooseobjects.Looseobjectsinthecaborsleepercanbedangerousina suddenstoporonbadroads.Secureanyapplianceaddedtothevehicle,suchasa refrigeratororaradio.

WARNING

Keepclearoffanwhenengineisrunning.Fanmaystarttorotateathighspeed withoutwarning.

28SAFETYINFORMATION

CERTIFICATIONLABELS

SafetyCerticationLabel

NationalHighwayTrafcSafetyAdministration(NHTSA)regulationsrequire afxingacerticationlabeltoallvehicles.

NHTSAregulationsalsorequirethatthecerticationlabelbeafxedtoeither thehingepillar,doorlatchpostorthedooredgethatmeetsthedoorlatch postnexttothedriverseat.Ifnoneoftheselocationsarepractical,itmaybe attachedtotheleftsideoftheinstrumentpanelortoaninwardfacingsurface ofthedriver-sidedoor.

IncompliancewithNHTSAregulations,yourMack®vehiclehasasafety certicationlabelafxedinoneoftheNHTSAlocationslistedabove.This labelmaybeeitheranIncompleteVehicleand/orCompletedVehiclelabel. Bothlabelsaredescribedbelow.

IncompleteVehicles

C0028955

Achassis-cabisanincompletevehiclewithacompletedoccupant compartmentthatrequirestheadditionofcargo-carrying,work-performingor load-bearingcomponentstoperformitsintendedfunctions.

Thechassis-cabmanufacturermustafxalabeltotheincompletevehiclein oneoftheNHTSAlocationslistedabove.Thislabelprovidesthechassis-cab dateofmanufacture,VINandvehiclecerticationinformation.

SAFETYINFORMATION29

CompletedVehicles

InadditiontothelabelsuppliedbyMackTrucks,Inc.asthechassis-cab manufacturer,aCompletedVehiclecerticationlabel,suppliedbythebody manufacturer,isafxedinthesamegenerallocation.Thislabelprovides informationpertainingtoGrossVehicleWeightRating(GVWR),GrossAxle WeightRating(GAWR),tireandriminformation,etc.

OnMACK-completedvehicles,thislabelcontainsthedateofmanufacture, VIN,GVWR,GAWR,andtireandrimdata.ItisfoundinoneoftheNHTSA locationslistedabove.

C0028956

30SAFETYINFORMATION

ADVISORYLABELS

ThroughoutthisbookyouwillndparagraphslabeledDanger ,Warning, Caution,NoteandServiceHint.Danger,CautionandWarninglabelsare

alsofoundinvariouslocationsonthevehicletoalertdrivers,operatorsand servicetechnicianstosituationswhichcancausepersonalinjuryorequipment damage.ThelabelsshownareapplicabletotheMack®TerraPro™LEU modelchassisatthetimeofpublicationandarerepresentativeofwhatcanbe typicallyfoundonaMack®T erraPro™LEU.(Y ourvehiclemaynotcontainall ofthelabelsillustratedinthishandbook.)Theselabelsareforyourbenet. Pleaselookthroughthissectionandnotethelabels,theirlocationsandwhat theyexplain.Besuretoreplaceanylabelthatisdamaged.

AdvisoryLabelLocations(OnVehicle)

LabelsFoundonChassis

C0029556

SAFETYINFORMATION31

C0029557

32SAFETYINFORMATION

C0029558

SAFETYINFORMATION33

C0029559

34SAFETYINFORMATION

LabelsFoundonDriver-SideSunVisor

C0029560

LabelsFoundonCowl(NearAshtray)

SAFETYINFORMATION35

C0029561

36SAFETYINFORMATION

LabelsFoundonInstrumentPanel

C0029017

C0029562

EatonControlledTractionDifferentialLabel

LabelsFoundonFuelTank

SAFETYINFORMATION37

C0029020

C0029021

38SAFETYINFORMATION

BackUpAlarm(Optional)

Yourchassismaybeequippedwithanoptionalbackupalarm.Ifso,the followinglabelwillappearinsidethecab.

C0029022

C0029563

SAFETYINFORMATION39

CABENTRY/EXIT

Three-LimbContact

WARNING

Whenenteringorexitingacab,thedriverand/orpassengermusthaveatleast threelimbsincontactwiththevehicleorgroundatalltimes.Thismeansthata minimumoftwohandsandonefoot,oronehandandtwofeetmustbeinFIRM contactwiththevehicleorground.

WARNING

Whenenteringorexitingthecab,beawareoftheconditionofthestepsand handrails.Cleananyfuel,oilorgreaseoffofthestepsbeforeenteringthecab. Duringcoldweatheroperation,iceandsnowmayaccumulateandshouldbe cleanedofftopreventslipping.

Duringcold,wetconditionswhenice,slush,orsnowmayaccumulateonthe cabdoorstepandotherexternalsurfaces,extracautionmustbeobserved whenenteringorexitingthecab.

WARNING

GUIDELINESFORENTERINGANDEXITINGTOA VOIDSERIOUS INJURY

•FacethecabwhenenteringANDexiting.

•Placepapers,coats,etc.,incabBEFOREentering.TakeoutAFTERexiting. Keephandsfreetogriphandholds.

•Keephandsandshoesclean.Checkhandsandshoesforgrease,mud,etc., BEFOREenteringorexiting.

•Keep3limbs(2handsand1footor1handand2feet)inFIRMcontactwithsteps andhandholdsatALLtimes.

•Besureofwhereyoustepandgrabthehandholds.Keeptheareasclean.

•BeEXTRAcarefulinrainy,snowy,etc.,weather.

•DoNOTjumpfromvehicle.

40SAFETYINFORMATION

Note:Theillustrationsonthefollowingpagesaretypicalforpurposesofemphasizing asafemethodforhand/footplacementandmovementduringcabentry/exit.Y our vehiclemaynotlookexactlyliketheonepictured.

Note:Thearrowsintheillustrationsareintendedtoshowmovement.Noticethat three-limbcontactismaintainedevenwhenonefoot,oronehand,ismoving.

SAFETYINFORMATION41

DriverSide

Thefollowingcabentryandexitprocedures,alongwiththesafetyguidelines outlinedinThree-LimbContactearlierinthissection,shouldbeusedwith thisMACKvehicle.

Entry

Theseentryproceduresareillustratedonthefollowingpage:

1Withbothfeetrmlyontheground,grabtheoutsidehandholdwithonehandand

grabtheinsidehandholdwiththeotherhand.Thenraiseonefoottothebottom step.(Seegure1.)

2Movehand[1]fromtheinsidehandholdtothesteeringwheel,thenraiseyour

otherfoottothecaboor .(Seegure2.)

3Movehand[2]fromtheoutsidehandholdtothesteeringwheel.(Seegure3.)

4Bringtheotherfootinsidethecabandsitdown.(Seegure4.)

Exit

Toexit,followtheillustrationsinreverseorder:

1Withbothhandsgrippingthesteeringwheel,standupandfacetheinsideofthe

cab.Moveonefoottothebottomstep.(Seegure4.)

2Moveonehandtotheoutsidehandholdandcontinuetogripthesteeringwheel

withtheotherhand.(Seegure3.)

3Withonefootrmlyonthebottomstep,lowertheotherfoottotheground.(See

gure2.)

4Withbothhandsrmlygrippingthehandholds,lowertheotherfoottotheground.

(Seegure1.)

42SAFETYINFORMATION

C0029564

SAFETYINFORMATION43

PassengerSide

Thefollowingcabentryandexitprocedures,alongwiththesafetyguidelines outlinedintheThree-LimbContactsection,shouldbeusedwiththisMACK vehicle.

Entry

Theseentryproceduresareillustratedonthefollowingpage:

1Grabthehandholdwithonehand,andplacetheotherhandonthesteeringwheel.

Donotusethefoldingdoorasahandhold.Raiseonefoottothecaboor.(See gure1.)

2Whilestillgrippingthehandholdandthesteeringwheel,movetheotherfootinto

thecab.(Seegure2.)

Exit

Toexit,followtheillustrationsinreverseorder:

1Gripthehandholdwithonehand,andthesteeringwheelwiththeotherhand.Then

moveonefoottotheground.(Seegure2.)

2Whilestillgrippingthehandholdandsteeringwheel,movetheotherfoottothe

ground.(Seegure1.)

C0029565

44SAFETYINFORMATION

SAFETYTIPSFORCOLDWEATHEROPERATION

DriverVisibility

Poordrivervisibilityisnotonlyannoying,butextremelyunsafeunderany circumstance.Withoutpropermaintenanceofvisibility-relatedcomponents, adverseweatherconditionssuchasrain,snowandfrostcanseriouslyreduce visibility.T aketimebeforewinterarrivestocheckthefollowing:

•WindshieldWipers

―Checkwindshieldwiperoperationandspeeds.

―Inspectconditionandtravelofblades.Installnewrellsforanybladesthatare cracked,brittle,torn,orcoatedwithroadoilalongthewipingedge.

•WindshieldWashers

―Checkoperationofwindshieldwasher .

―Inspectsystemhosesandreplaceifbrittleorworn.

―Inspectwasherreservoir.Drainandushifdirtparticlesareevidentinwasher solution.

―Fillreservoirwithcommerciallyavailablenon-freezingtypewasheruid.

CAUTION

DoNOTllreservoirwithwateronly.Eventhoughnon-freezingtypewasheruid isrecommended,donotattempttoclearthewindshieldoficebyactivatingthe windshieldwasherandwipers.Iceaccumulationsshouldberemovedmanually byusingascraper.

SAFETYINFORMATION45

•Heater/Defroster

―Checkoperationandblowersforspeedcontrol,noiseandtemperature.

―Inspectheatercoreforsignsofcorrosionand/orleakage.

―Checkthatthedefrosterblenddoorisoperatingcorrectlyandthatallducting isconnectedproperly.

―Besurethatventsarenotobstructedbydebrisorotherobjects.

CabDoorSealsandKeyLocks

Hollow-corerubberweathersealsaroundsomecabdoorsmaylosetheir resilienceinextremelycoldtemperatures(i.e.,–40°C/–40°Fandbelow). Undertheseconditions,itmaybenecessarytodrillholestopenetrate thehollowcore.Thisallowsentrappedairtoescape,therebyeasingthe opening/closingofcabdoor(s).

Besuretokeepthekeylockscleananddrytopreventoccasionalwinter freeze-up.Useofantifreezelubricantsisneitherrequirednorrecommended.

OutsideMirrorHeater

Inareasoffrequentsnowfallandice,itmaybebenecialtoinstallheated mirrorswhichwilldefrostandde-icecabmirrors.Heatedmirrorseliminatethe needtopulloffthehighwayandstandontheroadsidetoscrapeiceandsnow fromthemirrorsduringwinterdrivingconditions.Heatedmirrorsareavailable eithercabmountedorfendermounted.

C0029132

46SAFETYINFORMATION

AirHornSnowShield

Installationofanairhornsnowshieldisrecommendedtopreventsnowfrom cloggingtheairhornbell(maintainingmaximumsoundoutput).

C0029133

FireExtinguisher(Optional)

Yourvehiclemaybeequippedwithareextinguisherwhichislocatedinside yourcab.Checkyourreextinguisherregularlytomakesureitisfullycharged.

CABINTERIOR—LEFT

INSTRUMENTSANDCONTROLS47

1.TurnSignal,HazardSwitchand HI/LOBeam

2.InstrumentPanels

C0029566

3.FootPedals

48INSTRUMENTSANDCONTROLS

CABINTERIOR—RIGHT

1.InstrumentPanels3.FootPedals

2.WorkBrake

C0029567

4.TurnSignal,HazardSwitchand HI/LOBeam

INSTRUMENTSANDCONTROLS49

INSTRUMENTP ANEL

Tell-Tales

Atell-taleisadisplaythatindicatestheactuationofadevice,acorrector defectivecondition,orafailuretofunction.

Theoperatorshouldbecomefamiliarwiththesesymbolsinordertorecognize andreact(ifnecessary)totheindicatedcondition.Tell-talesymbolsareshown intheinstrumentpanelillustrationsonthefollowingpages.

Colors

Topromotevisualrecognitioninternationally ,speciccolorsfortell-tales havebeenestablished.Unlessgovernmentalregulations(intheareawhere thevehicleistobeused)orengineeringdirectivesspecifyotherwise,the standardcolorsare:

•Blue–high-beamheadlights/enginemaintenance

•FlashingGreen–turnsignals

•FlashingRed–hazardconditioninvolvingthesafetyofpersonnel

•SteadyGreen–systeminoperation

•SteadyRed–warning,immediateactionrequired

•Amber–earlywarning,suchaslowfuelorAnti-LockBrakeSystem(ABS) malfunction

50INSTRUMENTSANDCONTROLS

PanelArrangement

Yourviewfromthedriverseatshouldlooksomethingliketheillustrations shown.Thelayoutisdesignedtoprovidetheoperatorwithagoodviewofthe gaugesandcontrols(whichareplacedsotheyarewithineasyreach).The instrumentpanel,asshowninthefollowingdrawing,isbrokendowninto severalmainsections.Foreasyidenticationwerefertothem,fromleftto right,asPanelsA,B,C,D,EandF(wherenecessary).

Note:Thissectionshowstheinstrumentsandcontrolsavailableforthisvehicleatthe timeofpublication.However,dependingonoptions,yourvehiclemaynothaveall theinstrumentsandcontrolsshownhere,andtheymaynotbeinthesameposition.

INSTRUMENTSANDCONTROLS51

INSTRUMENTPANELGAUGELAYOUT

W3056176

52INSTRUMENTSANDCONTROLS

PanelsA,B,CandD

1.CoolantT emperatureGauge8.DEFGauge/FuelGauge

2.T achometer

3.OilPressureGauge

4.Warning/IndicatorLampPanel11.TransmissionOilTemperature

5.Speedometer/Odometer

6.HighBeamIndicator13.ModeButton

7.TurnSignalIndicators

9.AirPressureGauge

10.ParkingBrakeValve

Gauge

12.Voltmeter

14.HourMeter

W3056177

INSTRUMENTSANDCONTROLS53

PanelE

15.CBRadioAuxiliaryHookup25.AuxiliarySwitch—BodyFunction

16.DPFSmartSwitch(IfEquipped)26.LightControlPanel

17.Inter-AxlePowerDividerLockout Switch(IfEquipped)

18.TelmaRearAxleMounted Retarder(IfEquipped)

19.WindshieldWiper/WasherControl Switch

20.AutomaticTractionControl Switch/HeavyMud/Snow

21.CabClimateControlPanel31.Resume/SetSwitch

27.CombinationStarterandElectrical Switch

28.Right-HandOperationSwitch

29.Moto-MirrorSwitch(IfEquipped)

30.HeatedMirrorSwitch(If Equipped)

C0029589

22.PowerT ake-OffControlSwitch(If Equipped)

23.AuxiliarySwitch—BodyFunction33.CigarLighterorAccessoryPower

24.ParkingBrakeValve

Note:IfequippedwithAutomaticTractionControl(A TC),thecontrolswitchwill belocatedoninstrumentpanelE.Referto“AutomaticTractionControl(A TC)(If Equipped)”,page130oftheOPERATIONsectionofthismanualforA TCoperation andheavymud/snowoption.

32.SpeedControlSwitch

Outlet

54INSTRUMENTSANDCONTROLS

PanelF

C0029590

34.AirPressureGauge35.Speedometer/Odometer

1.CoolantTemperatureGauge—Indicatesthetemperatureoftheengine coolant.ThenormaloperatingtemperatureforMACKMP7engineisbetween 77°Cand107°C(170°Fand225°F).Thedriverwillreceiveawarningif coolanttemperaturereaches223°Fandengineshutdownwilloccurat227°F iftheenginecoolanttemperatureshutdownoptionisenabled.

CAUTION

CoolanttemperaturemustNOTexceed107°C(225°F).

2.Tachometer—Indicatesenginespeedinrevolutionsperminute(RPM). Tachometerreadingsshouldbeusedasaguideforshifting,aswellasto preventenginedamageduetooverspeed.Thebluebandindicatesthe optimumrangeforenginebrakeoperation.

3.OilPressureGauge—Indicatesengineoilpressure.Thenormal operatingoilpressureforaMACKMP7engine(atgovernedspeed)is between275.8and620.5kPa(40and90psi).Atidlingspeed,theoilpressure shouldbebetween275.8and413.9kPa(40and60psi).

Shouldtheoilpressuredropsuddenlyfromnormalreadings,stoptheengine immediatelyanddeterminethecause.

INSTRUMENTSANDCONTROLS55

4.Warning/IndicatorLampPanel–Itemslistedbelowfromlefttorightand

toptobottom.

W3056178

DetailofWarning/IndicatorLightPanel–LH

•OptionalT ell-T ales

•MalfunctionIndicatorlamp(MIL)—MILindicatesgovernmentRegulation OnBoardDiagnostics(OBD)faults.Lampremainsactiveafterrepairuntil systemoperationconrmsrepair.

•ElectronicMalfunctionIndicator(Amber)—IlluminateswhenV-MAC® detectsanelectronicmalfunction.RefertotheappropriateV-MAC® Operator’sGuidefordetails.

•EngineShutdownIndicator(Red)—Indicatestheoccurrenceofa conditionwhichrequiresthattheenginebeshutdown(i.e.,lowwaterlevel, lowoilpressureorhighwatertemperature).Iftheengineshutdownfeature isenabled,theoperatorhasabout15secondsafterthelightgoesontopull tothesideoftheroadbeforetheengineshutsoff.Iftheengineshutdown featureisdisabled,theindicatorwillfunctionasawarninglightbuttheengine willnotshutdown.

•OptionalT ell-T ales

•AftertreatmentDEFtankLowLevelIndicator(DEF)—Illuminateswhen theuidlevelislow.ItalsoFlasheswhenthelevelbecomescriticallylow.

•ReverseIndicator—IndicatesthatthetransmissionisinReverse.

•OptionalT ell-T ales

•LowAirPressureWarningIndicator—Indicateslowairpressureintheair brakesystem(s).Thisfeaturemayalsocomewithabuzzer.

•ParkingBrakeIndicator—Indicatesthattheparkingbrakeisengaged.

56INSTRUMENTSANDCONTROLS

•OptionalT ell-T ales

•HESTIndicator(Amber)—TheHighExhaustT emperature(HEST)indicator isdisplayedwhentheexhausttemperaturereaches300°C(572°F)andthe regenerationprocessbegins.Whentheregenerationprocessiscompleted, theengineshouldbeallowedtorununtiltheHESTindicatorshutsoff.

Duringregenerationwhilethevehicleismoving,theHESTindicatorwillonly illuminatewhenvehiclespeedislessthan8kph(5mph).

Duringaparkedregeneration,theHESTindicatorwillturnoffwhen regenerationiscompleteandtheexhausttemperaturehasreturnedtoa normaltemperature.

C0029146

HESTIndicator

•NeutralIndicator—IndicatesthatthetransmissionisinNeutral.

•OptionalT ell-T ales

•Anti-LockBrakeSystem(ABS)Indicator(Amber)—IndicatesanABS malfunction.Alsoilluminatesmomentarilyasabulbcheckwhentheignition isturnedon.Ifthelightturnsonandstayson,amalfunctionisindicated.If thelightdoesnotturnonwhentheignitionisturnedon,thebulbandthe powersourcemaybedefective.Foradditionalinformationonoperatingan ABS-equippedvehicle,referto“Anti-LockBrakeSystem(ABS)”,page127, intheOPERA TIONsection.

Note:WhenanABSmalfunctionisdetected,anti-lockbrakingintheaffectedwheel willbedisabledandnormalbrakingwillreturn;theotherwheelswillretainanti-lock braking.

•AutomaticT ractionControl(ATC)Indicator—IndicatesthatA TCis operating.

•OptionalT ell-T ales

•AftertreatmentDPFRegenerationRequiredIcon—Flasheswhenthe DieselParticulateFilterisfulloroverfullandregenerationisneeded.The iconasheswhenthelteris

•CheckTransmissionWarningIndicator(IfEquipped)—Onlypresenton vehiclesequippedwithautomatictransmission.

•OptionalT ell-T ales

INSTRUMENTSANDCONTROLS57

•Right-HandOperationIndicator—Indicatesthataright-handdrivemode hasbeenenabled.

•MaintenanceDueIndicator—Indicatesthatamaintenancealerthasbeen issued(maintenanceisdue).

•OptionalT ell-T ales

•AftertreatmentDPFRegenerationInhibitIcon—Illuminateswhenthe inhibitswitchisturnedon.Itwillallowthedrivertoknowthattheswitchisina inhibitpositionandaregenerationwillnotoccur.

•ForcedNeutralIndicator—IlluminateswhenPTOisengagedandthe truckisnotmoving.

•FuelFilterRestriction(IfEquipped)

•AirFilterRestriction(IfEquipped)

•PredictiveOilChange(IfEquipped)

•EngineOilLevelIndicator—Ifilluminated,immediatelycheckthelevelof yourengineoil.

•WaterinFuelIndicator(IfEquipped)—Illuminateswhenwater accumulatesintheprimaryfuelltersedimentbowl.Stoptheengineand drainthefuelfromthesedimentbowl.

DetailofWarning/IndicatorLightPanel–RH

•OptionalT ell-T ales

W3056183

58INSTRUMENTSANDCONTROLS

•MalfunctionIndicatorlamp(MIL)—MILindicatesgovernmentRegulation OnBoardDiagnostics(OBD)faults.Lampremainsactiveafterrepairuntil systemoperationconrmsrepair.

•ElectronicMalfunctionIndicator(Amber)—IlluminateswhenV-MAC® detectsanelectronicmalfunction.RefertotheappropriateV-MAC® Operator’sGuidefordetails.

•OptionalT ell-T ales

•AftertreatmentDEFtankLowLevelIndicator(DEF)—Illuminateswhen theuidlevelislow.ItalsoFlasheswhenthelevelbecomescriticallylow.

•ReverseIndicator—IndicatesthatthetransmissionisinReverse.

•OptionalT ell-T ales

•LowAirPressureWarningIndicator—Indicateslowairpressureintheair brakesystem(s).Thisfeaturemayalsocomewithabuzzer.

•ParkingBrakeIndicator—Indicatesthattheparkingbrakeisengaged.

•OptionalT ell-T ales

•HESTIndicator(Amber)(IfEquipped)—TheHighExhaustT emperature (HEST)indicatorisdisplayedwhentheexhausttemperaturereaches300°C (572°F)andtheregenerationprocessbegins.Whentheregenerationprocess iscompleted,theengineshouldbeallowedtorununtiltheHESTindicator shutsoff.

•NeutralIndicator—IndicatesthatthetransmissionisinNeutral.

•OptionalT ell-T ales

•AutomaticT ractionControl(ATC)Indicator—IndicatesthatA TCis operating.

•OptionalT ell-T ales

INSTRUMENTSANDCONTROLS59

•AftertreatmentDPFRegenerationRequiredIcon—Illuminateswhenthe DieselParticulateFilterisbecomingfullandregenerationisneeded.Theicon asheswhenthelterisfulloroverfull.

•CheckTransmissionWarningIndicator(IfEquipped)—Onlypresenton vehiclesequippedwithautomatictransmission.

•OptionalT ell-T ales

•Right-HandOperationIndicator—Indicatesthataright-handdrivemode hasbeenenabled.

•CoolantTemperatureGauge—Indicatesthetemperatureoftheengine coolant.ThenormaloperatingtemperatureforMackenginesisbetween77°C and107°C(170°Fand225°F).Thedriverwillreceiveawarningifcoolant temperaturereaches223°Fandengineshutdownwilloccurat227°Fifthe enginecoolanttemperatureshutdownoptionisenabled.

•OptionalT ell-T ales

•AftertreatmentDPFRegenerationInhibitIcon—Illuminateswhenthe inhibitswitchisturnedon.Itwillallowthedrivertoknowthattheswitchisina inhibitpositionandaregenerationwillnotoccur.

•ForcedNeutralIndicator—IlluminateswhenPTOisengagedandthe truckisnotmoving.

TurnSignalIndicatorLH—Flashgreenwhentheturnsignalsareactivated.

HighBeamIndicator(Blue)—Indicatesthathighbeamsareon.

TurnSignalIndicatorRH—Flashgreenwhentheturnsignalsareactivated.

•EngineOilLevelIndicator—Ifilluminated,immediatelycheckthelevelof yourengineoil.

•WaterinFuelIndicator(IfEquipped)—Illuminateswhenwater accumulatesintheprimaryfuelltersedimentbowl.Stoptheengineand drainthefuelfromthesedimentbowl.

5.Speedometer/Odometer—Indicatesroadspeedinmilesand/or kilometersperhourandtotaldistancevehiclehastraveled.

6.HighBeamIndicator(Blue)—Indicatesthathighbeamsareon.

7.TurnSignalIndicators—Flashgreenwhentheturnsignalsareactivated.

8.Fuel/DEFGauge—RegistersthefuelandDEFlevelsinthesupplytank(s).

60INSTRUMENTSANDCONTROLS

9.AirPressureGauge—Indicatestheairpressureintheairbrake

system(s).Thenormaloperatingairpressureisbetween759kPa(110psi) and897kPa(130psi)inbothairbrakesystems.Ifpressuredropsbelow75 psi(±5psi)ineithersystem,thewarningbuzzerandwarninglightwillgo on.Determinethecauseoffailurebeforeproceeding.Primaryairpressure issuppliedtotherearbrakesandisindicatedbythegreenpointeronthe gauge.Secondaryairpressureissuppliedtothesteeringaxlebrakesand indicatedbytheorangepointer.

10.ParkingBrakeValve—Yellowdiamond-shapedknob.Pulltoapply. Pushtorelease.Appliesparkingbrakes.

11.TransmissionOilTemperatureGauge—Indicatesthetemperature oftheautomatictransmissionoil.Thenormaloperatingrangeisbetween 71°Cand93°C(160°Fand200°F).Ifthetransmissionoiltemperature reaches121°C(250°F),operationinthehighergearswillbeinhibited.Ifthe transmissionoverheatsduringnormaloperation,stopthevehicleandcheck thetransmissionoillevel.Ifboththetransmissionoiltemperaturegaugeand theenginecoolanttemperaturegaugeindicateahightemperature,checkthe coolingsystem.Ifthecoolingsystemappearstobefunctioningproperly,shift thetransmissionintoNeutral,settheparkingbrakes,andruntheengine between1200and1500rpm.Theengineandtransmissionshouldcool sufcientlywithintwotothreeminutes.Ifthetemperaturedoesnotdropto operatingrange,theconditionmustbeinvestigatedandcorrectedbefore continuingoperation.

12.V oltmeter—Indicatesthesurfacechargeofthebatterywiththeengine NOTrunning(andtheignitionON).Indicatestheconditionofchargingsystem withtheenginerunning.

Thevoltmetercanbeusefulasadiagnostictool.Duringcranking,thereading shouldnotdropbelow10volts.Lowerreadingsmayindicatecorroded connectionsatthecrankingmotororbatteryterminals,ordischargedor defectivebatteries.

13.ModeButton—Usingthisbuttonwilldisplaydiagnostictroublecode informationandtripdistanceintheodometer.Whenyoupressandholddown thisbutton,thedisplaywillgothroughagaugeselftest.Aftertheselftestis complete,diagnostictroublecodeinformationwillbedisplayed,byMID,inthe speedometer/odometerscreen.WhentherstMIDisdisplayed,pushthe Modebuttonagaintodisplaythe1stdiagnostictroublecodeforthisMID. AttheendofthediagnostictroublecodelistforeachMID,"CLEAR"willbe displayed.YouhavetheoptionheretoclearthecodesforthisMID.Ifyou choosetodoso,pressandholdtheModebutton.Oncethecodesarecleared forthisMID,thenextMIDwillbedisplayed.

Bypressingthisbuttononce(NOTholdingitdown),informationforTrip1 distancewillbedisplayed.PressandholdtheModebuttontoclearTrip1 information.

Bypressingthisbuttontwice,informationforTrip2distancewillbedisplayed. PressandholdtheModebuttontoclearTrip2information.

INSTRUMENTSANDCONTROLS61

14.HourMeter—Indicateshoursofengineoperation.Hoursofoperation

shouldbeusedasaguideforcertainengineorPTOmaintenanceoperations.

15.CBRadioAuxiliaryHookup

16.DPFSmartSwitch(IfEquipped)—Thisisathree-positionswitchwhere

themiddlepositionisneutral.

C0029592

1.UpperPosition—Regeneration Position

2.MiddlePosition—NeutralPosition

3.DownPosition—InhibitPosition

62INSTRUMENTSANDCONTROLS

DPFINHIBITROADSPEEDLIMITING(RSL)

TheDPFSmartSwitchcanbelockedintotheDOWN(orInhibitRegen) positionbythedriver.IftheDPFSmartSwitchremainsinthelockedposition, thefollowingvehiclespeedlimitingwilloccur:

1VehicleMoving.IfvehicleismovingwiththeDPFSmartSwitchinthelocked

(DOWN)position,thevehiclespeedwilldecreasedownto16kph(10mph)below thecurrentspeeduntilthedriverreleasestheswitchbacktotheneutral(MIDDLE) position.

2VehicleStationaryandthenMoving.IfthevehicleisstationarywiththeDPF

SmartSwitchinthelocked(DOWN)positionandthedriverthenbeginstomove thetruck,thevehiclespeedwillbelimitedto16kph(10mph)untilthedriver releasestheswitchbacktotheneutral(MIDDLE)position.

INSTRUMENTSANDCONTROLS63

17.Inter-AxlePowerDividerLockoutSwitch(IfEquipped)—See

Inter-AxlePowerDividerLockoutintheOPERATIONsectionofthishandbook on.

C0029594

18.T elmaRearAxleMountedRetarderIndicatorLamp(IfEquipped)—

TheT elmadoesnothaveadisableswitch.Itisalwaysonandwilloperate atdifferentlevelsdependingonapplicationofservicebrake.Theindicator willshowyouthelevelyouareretardingthevehicle:20%,40%,60%,80% or100%.

Note:TheTelmaretarderisdisabledifthereisanABSevent.

C0029217

TelmaRetarder

64INSTRUMENTSANDCONTROLS

19.WindshieldWiper/WasherControls—DepresstheON/OFFbuttonto

turnthewindshieldwipersonoroff.Pullthebuttonuptomakethewipers faster,pushthebuttondowntomakethewipersslower.Depressthe"WASH" buttontoactivatethewasheruid.

C0029595

20.AutomaticTractionControlSwitch/HeavyMud/Snow—Activatefor increasedtractioncontrolinheavymudorsnow.(See“AutomaticTraction Control(ATC)(IfEquipped)”,page130intheOPERATIONsectionofthis manualformoredetails.)Whentheoperatorpressesthetopoftherocker switch,theheavymud/snowfunctionATCindicatorlampblinkscontinuously . TheA TClampstopsblinkingwhentheATCmodeswitchispressedagain orignitionkeycycled.

CAUTION

Besuretodeactivatetheheavymud/snowfunctionwhennolongerneeded. Continuedoperationwiththeheavymud/snowfunctionactivewillresultinvehicle damage.Ifafterareasonableamountoftime(nomorethanveminutes)the vehicleisstillnotmoving,deactivatetheATCandputonchains.

21.CabClimateControlPanel—SeetheCABCLIMATECONTROL sectionformoreinformation.

22.PowerTake-OffControlSwitch(IfEquipped)—Pushthetopintoturn thePTOon.Pushthebottomintoturnitoff.

C0029596

23.AuxiliarySwitch—AsdenedbytheBodyBuilder.

INSTRUMENTSANDCONTROLS65

24.ParkingBrakeValve—Pulltoapply.Pushtorelease.Appliestractor

parkingbrakesandtrailerbrakes,ifequipped.

25.AuxiliarySwitch—AsdenedbytheBodyBuilder.

26.LightControlPanel—SeetheLIGHTCONTROLPANELsectionfor

moreinformation.

27.CombinationStarterandElectricalSwitch—Startstheengineand activatestheaccessoryrelay.Tostarttheengine,turnkeyclockwise.T o activatetheaccessories,turnthekeycounterclockwise.Whentheswitchis turnedON(ineitherdirection),awarningbuzzerwillsoundifairpressureis below448±34kPa(65±5psi);thebuzzerwillturnoffassoonassufcientair pressureisrestored.Whenthekeyisstraightupanddown,theswitchisOFF .

28.Right-HandOperationSwitch—Allowstheoperatortoswitchtoa right-handdrivemode.T ouse:

Note:Speedisrestrictedto2ndgearwhenoperatingthevehiclefromtheright-hand side.

-Stopthevehicle.

-PutthetransmissioninNEUTRAL.

-Settheparkingbrake.

-Gototherightsideofthevehicle.

-Fliptheswitchtotheright.

29.Moto-MirrorSwitch(IfEquipped)

C0029597

66INSTRUMENTSANDCONTROLS

30.HeatedMirrorSwitch(IfEquipped)—Activatestheoutsideheated

mirrors(foruseinicyconditions).

31.Resume/SetSwitch—ThisisaV-MAC®switch;formoreinformation, refertotheapplicableV-MAC®Operator’sGuide.

C0029598

C0029150

32.SpeedControlSwitch—ThisisaV-MAC®switch;formoreinformation, refertotheapplicableV-MAC®Operator’sGuide.

C0029211

33.CigarLighter—Pressinthelighter;itwillpopoutwhenelementishot.

CAUTION

Maximumamperageforthein-dashcigarlighteris10amps.DoNOTusethecigar lighterreceptacletopoweraccessoriesratedhigherthan10amps.

INSTRUMENTSANDCONTROLS67

AccessoryPowerOutlet—SeeinstructionsunderAccessoryPowerOutlets listedintheInstrumentandControlsSectionofthismanual.

34.AirPressureGauge—Indicatestheairpressureintheairbrake system(s).Thenormaloperatingairpressureisbetween759kPa(110psi) and897kPa(130psi)inbothairbrakesystems.Ifpressuredropsbelow75 psi(±5psi)ineithersystem,thewarningbuzzerandwarninglightwillgo on.Determinethecauseoffailurebeforeproceeding.Primaryairpressure issuppliedtotherearbrakesandisindicatedbythegreenpointeronthe gauge.Secondaryairpressureissuppliedtothesteeringaxlebrakesand indicatedbytheorangepointer.

35.Speedometer/Odometer—Indicatesroadspeedinmilesand/or kilometersperhourandtotaldistancevehiclehastraveled.

68INSTRUMENTSANDCONTROLS

CABCLIMATECONTROL

C0029599

1.FanControlSwitch3.T emperatureControlLever

2.ModeSelectionLever

1.FanControlSwitch—Controlstheamountofairdeliveredthroughthe vents.DownisOFFandupisHIGHspeed.ThemiddlepositionsareLOW andMEDIUMspeeds.

2.ModeSelectionLever—Allowstheoperatortochoosetheairdirection. TheCABpositiondeliversairtotheooroutlets,whiletheDEFposition directsairtothewindshieldfordefoggingand/ordefrosting.Slidingthelever inbetweenpositionsprovidesablendofthetwo.

3.TemperatureControlLever—ControlsthetemperatureofairfromCOOL (farleft)toHOT(farright).

INSTRUMENTSANDCONTROLS69

LIGHTCONTROLPANEL

Thispanelcontrolstheparkinglights,interiorpanellights,headlightsand foglights(ifequipped).

C0029600

1.LightControlKnob/PullforFog

2.PanelDimmerSwitch

Withthelightcontrolknobintheleftposition,alllightsareoff.Withtheknobin themiddleposition,theparkinglightsandinteriorpanellightswillilluminate. Withtheknobinthefarrightposition,theheadlightswillturnon.

Toturnonthefoglights(ifequipped),puttheknobinthefarrightposition andpulloutthefoglightbutton(seeFigureabove).Thefoglightsymbolwill illuminateindicatingthelightsareon.

Toadjusttheintensityofthepanellight,movethepaneldimmerswitchback andforth.

Toturnonthehook-uplampsorperimeterlighting(ifequipped),pushthe rightswitchup.

3.Hook-UpLampsorPerimeter Lighting(IfEquipped)

70INSTRUMENTSANDCONTROLS

STEERINGCOLUMN

CombinationStarterandElectricalSwitch

TurnSignalLever

Note:Theturnsignalsarenotself-cancellingandmustbereturnedtothemiddle positionmanually .

Theturnsignalleverislocatedonthesteeringcolumn.Itperformsanumber offunctions,includingactivatingthehighandlowbeamsandthehazard switch(seeillustrationonfollowingpage).

C0029601

1.HandleinRightTurnPositionand CancelPositionofHazardWarning

2.HandleinLeftTurnPositionand CancelPositionofHazardWarning

3.PullforWarningHazardPosition

4.PushButtonforHi/LoBeam

INSTRUMENTSANDCONTROLS71

MISCELLANEOUSCONTROLS

DomeLight

C0029602

Pushtheswitchtotherighttoturnthedomelighton.Pushtheswitchtothe lefttoturnthedomelightoff.

AirHorn

C0029603

Theairhorn(s),ifequipped,isactivatedbypullingdownonthecordthatis locatedabovethedriverneartheoverheadconsole.

72INSTRUMENTSANDCONTROLS

FreshAirVent

C0029604

Anairvent,locatedinthedriversidedoor,isprovidedtocirculateoutsideair tothecabinterior.Movetheventleverforwardorrearwardtoopenthevent. Movethelevertothecentertoclosethevent.

AccessoryPowerOutlets

Additional12-voltaccessorypoweroutletsarelocatednexttothedriveronthe "E"panel.Thesecigarlight-typeoutletssupply12voltsoffused(20A)power whentheignitionswitchisturnedtotheignitionoraccessoryposition.

CAUTION

Maximumamperageforallpowerreceptaclesincabis20amps.DoNOTexceed maximumamperageasequipmentdamagemayresult.

C0029605

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE73

PRE-TRIP

DANGER

Beforeworkingonorinspectingavehicle,settheparkingbrakes,placethe transmissioninneutralandblockthewheels.Failuretodosocanresultin unexpectedvehiclemovementandcancauseseriouspersonalinjuryordeath.

Safetyisthemostimportantandobviousreasonfordoingapre-tripinspection. Federalandstatelawsrequireinspectionperformedbythedriver.Federal andstateinspectorsalsoinspectcommercialvehicles.Anunsafevehiclecan beplaced"outofservice"untilthedriverorownercorrectsthedeciency. Ownersandoperatorsshouldfamiliarizethemselveswithsections49CFR

396.11and396.13concerningFederalrequirementsforvehicleinspection. Certainotherlawsmayalsoapply.

Section49CFR396.13statesthatallmotorcarrierdriversmustcompletea writtenreportattheendofeachworkdayforeachvehicleoperated,covering mostofwhatiscoveredinthepre-triplist.Thereportshouldlistalldefects ordecienciesdiscoveredbythedriver.Apre-tripinspectionpreparesfor theend-of-workreport.

Startingonthenextpagearesuggestedguidelinestobeusedinperforming truck,tractorandtrailerpre-tripinspections.Dependingontheapplicationof thevehiclebeingused,theseguidelinesshouldbemodiedtoincludeother necessaryinspectionpoints.Forexample,stepsandgrabhandlesshouldbe checkeddailyonrefusetrucksbecausetheoperatorisgettinginandout ofthecabmorefrequently.

Ifanycomponentorsystemdoesnotpassthisinspection,itmustbecorrected beforeoperatingthevehicle.Wheneverequipmentrequiresadjustment, replacement,repairorlubrication,refertotheServiceManualsorcontact anauthorizedMackTruckdealerforthecorrectprocedures,specications andintervals.

Takeyourtimegoingthroughthepre-tripinspection.Rememberthatacareful pre-tripinspectionsavestimebyeliminatingunscheduledstopsforcorrecting afaultyitem.

ThefollowinginformationhasbeenprovidedbytheAmericanTrucking AssociationasdevelopedbytheD.O.T .OfceofMotorCarriers(BMCS).

Pre-TripInspectionQuickList

Inspectthevehicleinacircularmanner.

ApproachingtheVehicle

74PRE-TRIPINSPECTIONANDDAILY MAINTENANCE

•Checkunderthevehicleforoil,fuel,coolantleaksorothersignsofdamage.

•Checkbodysurfacesforsignsofbreaksordamage.

Preparation

•Opendraincocksonairtankstoletthetanksdrain.

•Chockwheelsonvehicleand,ifhookedup,trailer.

•Closeairtankdraincocks.

•Starttheengineandlettheairpressurebuilduptonormal.Stopengine checkforairleaks.

•Switchonparkinglightsandhazardlights.

•Applyparkingbrakes.Listenforairleaks

•Raisecabsobeltscanbechecked

Step1:LeftSideoftheCab

LeftFrontWheel

•Checkconditionofwheelrim.Especiallylookforcracks,missinglockrings, bentorbrokenstuds,missingclampsorlugnuts.

•Checkconditionoftire:properlyinated,noseriouscuts,bulges,tread wearoranysignsofmisalignment;valvestemnottouchingwheel,rimor brakedrum;valvecapinplace.

•Checkwheelbearingandhub:noobviousleakingonoutsideorinside wheel.Verifycorrectoillevelinhub.

LeftFrontSuspension

•Checkconditionofspring,springhangers,shackles,U-bolts:nocracks, breaksorshifting.

•Checkshockabsorbercondition.

LeftFrontBrake

•Conditionofbrakedrum.Withbrakesreleased,lookforanoticeablegap betweenlininganddrum.(Thischeckcannotbemadeifdustcoversare inplace.)

•Conditionofbrakeairhose.

•Checkbrakechambermountingboltsandbracket.

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE75

•Checkslackadjusterandchamberpushrodtravelforproperbrake adjustment.

ConditionofFrontAxleandSteeringSystem,LeftSide

•Noloose,worn,bent,damagedormissingparts.

EngineCompartment,LeftSide

•Checkcoolanthosecondition.

•Checkconditionoffandrivebelts.

•Checkengineandsurroundingareasforcoolant,oilandfuelleaks.

•Checkwiringharnessesforsignsofdamage.

EngineCompartment,RightSide

•Checkconditionofcoolantandheaterhoses.

•Checkconditionoffandrivebelts.

•Checkengineandsurroundingareasforcoolant,oilandfuelleaks.

•Checkfuelseparatorsightglassanddrainifnecessary.Checkforleaks.

•Checkwiringharnessesforsignsofdamage.

•Checkairlterwithbracketsandhosesforlooseconnectionsordamage. Checkltergauge,ifmountedonthelter.

Step2:FrontofCabArea

ConditionofWindshield

•Checkfordamageandcleanifdirty.

•Checkwindshieldwiperarmsforproperspringtension.

•Checkwiperbladesforanydamage,"dead"rubberandattachmenttoarm.

LightsandReectors

•Lowercabandinspectparking,clearanceandidenticationlightsoncab. Theyshouldbeclean,operatingandofthepropercolor.

•Reectorscleanandpropercolor.

•Turnonheadlights.Highandlowbeamsshouldbeoperatingandlenses clean.Ifequipped,checkdaytimerunninglights.

76PRE-TRIPINSPECTIONANDDAILY MAINTENANCE

•Leftandrightfrontturnsignallightsclean,operatingandpropercolor.

Grille

•Checkthatchargeaircoolerandradiatororbugscreensarecleanand undamaged.

Step3:RightSideofCabArea

RightFrontWheel

•Checkconditionofwheelrim.Especiallylookforcracks,missinglockrings, bentorbrokenstuds,missingclampsorlugnuts.

•Checkconditionoftire:properlyinated,noseriouscuts,bulges,tread wearoranysignsofmisalignment;valvestemnottouchingwheel,rimor brakedrum;valvecapinplace.

•Checkwheelbearingandhub:noobviousleakingonoutsideorinside wheel.Verifycorrectoillevelinhub.

RightFrontSuspension

•Checkconditionofspring,springhangers,shackles,U-bolts:nocracks, breaksorshifting.

•Shockabsorbercondition.

RightFrontBrake

•Conditionofbrakedrum.Withbrakesreleased,lookforanoticeablegap betweenlininganddrum.(Thischeckcannotbemadeifdustcoversare inplace.)

•Conditionofbrakeairhose:checkforanychang.

•Checkbrakechambermountingboltsandbracket.

•Checkslackadjusterandchamberpushrodtravel.Withbrakesapplied orreleased,lookforconspicuouslydifferentpositionsoftheslackadjusters forproperbrakeadjustment..

ConditionofFrontAxleandSteeringSystem,RightSide

•Noloose,worn,bent,damagedormissingparts.

Step4:RightSaddleTankArea

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE77

RightFuelT ank(s)

•SecurelymountedDieselandDieselExhaustFluidarenotdamagedor leaking.

•Fuellinessecureandnotleaking.Checkthatshut-offvalvesareopen.

•T ank(s)fulloffuel.Caponandsecure.

ConditionofVisibleComponents

•Rearofengine:notleaking.

•Transmission:notleaking.Ifequippedwithoilcooler,checkcooler,hoses andttingsforleaks.

•Checkdriveshaft.

•Exhaustsystem:secure,notleaking,nottouchingwires,fuelorairtubing.

•Frameandcrossmembers:nobends,cracksorbreaks.

DPF/SCRcheckhosesandttingsforleaks.

•Airtubingandelectricalwiring:securedagainstsnaggingandchang.

Step5:RightRearVehicleArea

DualWheels,OneorTwoAxles

•Checkconditionofwheelsandrims.Especiallylookforcracks,missing lockrings,bentorbrokenspacers,studs,missingclampsorlugnuts.

•Checkconditionoftires:properlyinated,noseriouscuts,bulges,tread wearoranysignsofmisalignment;valvestemsnottouchingwheels,rimsor brakedrums;valvecapsinplaceandnoobjectsstuckbetweenthewheels.

•Checkthatbothtiresareofsametype,forexample,notmixedradialand biastypeandthattheircircumferencesarematched.

•Checkwheelbearingandhub:noobviousleakingonoutsideorinsidewheel.

Suspension

•Checkconditionofsprings(leaf),springhangers,shacklesandU-bolts.

•Axlealignment.

Brakes

•Conditionofbrakedrums.Withbrakesreleased,lookforanoticeablegap betweenlininganddrum.(Thischeckcannotbemadeifdustcoversare inplace.)

78PRE-TRIPINSPECTIONANDDAILY MAINTENANCE

•Conditionofbrakehoses:checkforanychang.

•Checkbrakechambermountingboltsandbrackets.

•Checkslackadjustersandchamberpushrodtravel.Withbrakesapplied orreleased,lookforconspicuouslydifferentpositionsoftheslackadjusters forproperadjustment.

•Checkspringbrakes.

Step6:RearofVehicleArea

FrameArea

•Frameorcrossmembersnotbent,crackedorotherwisedamagedormissing.

•Checkthatairtubingandelectricallinesareproperlysecuredtotheframe withnodamageorchang.

LightsandReectors

•T aillights,brakelightsandturnsignallights:operating,cleanandproper color.

Step7:CouplingSystemArea

FifthWheel

•Securelymountedtotheframe.

•Nomissingordamagedparts.

•Checkthattrunnionandplateareproperlylubricated.

SlidingFifthWheel

•Mechanismnotworn,bent,damagedorpartsmissing.

•Properlylubricated.

•Alllockingpinspresentandlockedinplace.

•Ifairoperated:noairleaks.

AirT ubingandElectricLinesVisibleFromThisPoint

•Shouldbesecurefromdangling.

•Bothairlinesandelectriclineshouldbefreefromdamage,oilandgrease.

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE79

Step8:LeftSaddleTankandLeftRearVehicleWheelsArea

DualWheels,OneorTwoAxles

•Checkconditionofwheelsandrims.Especiallylookforcracks,missing lockrings,bentorbrokenspacers,studs,missingclampsorlugnuts.

•Checkconditionoftires:properlyinated,noseriouscuts,bulges,tread wearoranysignsofmisalignment;valvestemsnottouchingwheels,rimsor brakedrums;valvecapsinplaceandnoobjectsstuckbetweenthewheels.

•Checkthatbothtiresareofsametype,forexample,notmixedradialand biastypeandthattheircircumferencesarematched.

•Checkwheelbearingandhub:noobviousleakingonoutsideorinsidewheel.

Suspension

•Checkconditionofsprings(leaforair),springhangers,shacklesandU-bolts, nocracks,breaksorshifting.

Brakes

•Conditionofbrakedrums.Withbrakesreleased,lookforanoticeablegap betweenlininganddrum.(Thischeckcannotbemadeifdustcoversare inplace.)

•Conditionofbrakehoses:checkforanychang.

•Checkbrakechambermountingboltsandbrackets.

•Checkslackadjustersandchamberpushrodtravel.Withbrakesapplied orreleased,lookforconspicuouslydifferentpositionsoftheslackadjusters forproperbrakeadjustment..

•Checkspringbrakes.

ConditionofVisibleComponents

•Transmission:notleaking.

•Driveshaft:looksOK.

•Exhaustsystem:secure,notleaking,nottouchingwires,fuelorairtubing.

•Frameandcrossmembers:nobends,cracksorbreaks.

•Airtubingandelectricalwiring:securedagainstsnaggingandchang.

LeftFuelT ank(s)

•Securelymountedandnotdamagedorleaking.

80PRE-TRIPINSPECTIONANDDAILY MAINTENANCE

•Fuellinessecureandnotleaking.Checkthatshut-offvalvesareopen.

•T ank(s)fulloffuel.Caponandsecure.

BatteryArea

•Openthebatterybox.Batteryboxsecurelymountedtovehicle.

•Batteriessecuredagainstmovement.

•Batterycasesnotbrokenorleaking.Batterycablesfreefromdamage.

•T opsofbatteriesandterminalscleanandfreefromforeignmaterial.

•Ifequipped,replacebatterylidandmakesureitissecurelyfastened.

IntheCab

•Checkstepsandgrabhandlesforloosenessorbreakage.Also,clean themifthereisanysubstancethatmakesthemslippery ,whichmakescab entry/exithazardous.

•Starttheengine.Ifequipped,checkthatexhaustraincapopenswhen acceleratingengine.

•Checkgaugesandtell-talelightfunction.SeetheInstrumentsandControls section.

•Checkfunctionoflowairwarning.

•Checkclutchfunction.Ifequipped,checkforclutchbrakefunction.

•Checkwindshieldwipersandwashersandhorns,includingback-upalarm, ifequipped.

•Cleaninsidewindshield,doorwindowsandinstruments.Cleanmirrors.

•Checktemperaturecontrolanddefroster.Ifequipped,checkmirrorheater.

•Checkconditionofwarningtriangles,reextinguisherandares.

•Adjusttheseat.Checkmirroradjustment.

•Checksafetybeltsforfunctionanddamage.

•Applyservicebrakes.Afterinitialdrop,pressureshouldholdsteady,or increaseslightly,withengineatidle.

•Checksteeringwheelforexcessivefreeplay.

•Checkforlooseitemsinthecab.Securethemifnecessary .

HookingUpToTrailer

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE81

Hook-UpPreparation

•Checkkingpinandmountingplateontrailer,freefromwear,bendsor damage.

•Chocktrailerwheels.

FifthWheelorTrailerHitch

•Novisiblespacebetweenfthwheelandtrailer.

•Lockingjawsaroundtheshankandnottheheadofkingpin.

•Releaseleverproperlyseatedandsafetylatch/lockengaged.

•Checkallconnectionstodollyortrailerhitchandsafetychainsaresecured.

•Checkfunctionoftrailerairsupplyvalveandtrailerbrakes.

SlidingFifthWheel

•Checkthatfthwheelisnotsofarforwardthatthetractorframewillstrike thelandinggearduringturns.

Note:Refertothetrailermanufacturer’smanualforspecicinformationonthe trailerchecks.

Step9:TrailerFrontArea

AirandElectricalConnections

•Gladhandsproperlymounted,freefromdamageandnotleaking.

•Trailercordreceptacleproperlymounted,freeofdamage;plugproperly seatedandsafetycatchengagedtopreventaccidentaldisconnect.

•Airandelectricallinesproperlysecuredagainsttangling,snaggingand changwithsufcientslackforturns.

Step10:RightSideofTrailerArea

LandingGearorDollyArea

•Fullyraised;nomissingordamagedparts.

•Crankhandlepresentandsecured.

•Ifpoweroperated,noair/hydraulicleaks.

SpareWheel(s)

82PRE-TRIPINSPECTIONANDDAILY MAINTENANCE

•Carrierorracknotdamaged.

•Sparewheelsecurelymountedinrack.

•Tireandwheelconditionadequateforaspare:propersize,properlyinated.

LightsandReectors

•Trailersideclearancelights:clean,operatingandpropercolor.

•Reectorscleanandpropercolor.

FrameandBody

•Frameandcrossmembersnotbent,cracked,damagedormissing.

•Properplacarding.

•Bodypartsnotdamagedormissing.

Step11:RightRearTrailerWheel

DualWheels,OneorTwoAxles

•Checkconditionofwheelsandrims.Especiallylookforcracks,missing lockrings,bentorbrokenspacers,studs,missingclampsorlugnuts.

•Checkconditionoftires:properlyinated,noseriouscuts,bulges,tread wearoranysignsofmisalignment;valvestemsnottouchingwheels,rimsor brakedrums;valvecapsinplaceandnoobjectsstuckbetweenthewheels.

•Checkthatbothtiresareofsametype,forexample,notmixedradialand biastypeandthattheircircumferencesarematched.

•Checkwheelbearingandhub:noobviousleakingonoutsideorinsidewheel.

Suspension

•Conditionofsprings(leaforair),springhangers,shacklesandU-bolts.

•Axlealignment.

•Conditionoftorquerodarms.

•Ifequippedwithslidingaxles,checkpositionandalignment.Lookfor damaged,wornormissingparts,alllockspresent,fullyinplaceandlocked.

•Flexibleairtubingnotcracked,cut,crimpedorotherwisedamaged.Secured againsttangling,draggingandchang.

Brakes

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE83

•Conditionofbrakedrums.Withbrakesreleased,lookforanoticeablegap betweenlininganddrum.(Thischeckcannotbemadeifdustcoversare inplace.)

•Conditionofbrakehoses:checkforanychang.

•Checkbrakechambermountingboltsandbrackets.

•Checkslackadjustersandchamberpushrodtravel.Withbrakesapplied orreleased,lookforconspicuouslydifferentpositionsoftheslackadjusters forproperbrakeadjustment..

•Checkspringbrakes.

Step12:RearofTrailerArea

LightsandReectors

•Rearclearance,identicationandtaillightsclean,operatingandpropercolor.

•Reectorscleanandpropercolor.

CargoSecurement

•Cargoproperlyblocked,braced,tied,chained,etc.

•T ailboardupandproperlysecured.Endgatesfreefromdamage,properly securedinstakepockets.

•Canvasortarp(ifrequired)properlylatcheddowntopreventwaterdamage, tearing,billowingorblockageofeithermirrorsortaillights.

•Reardoorssecurelyclosed,latchedorlocked;requiredsecuritysealsin place.

•Undersideguardinplace:notcracked,bentorbroken.

Step13:LeftRearTrailerWheelsArea

DualWheels,OneorTwoAxles

•Checkconditionofwheelsandrims.Especiallylookforcracks,lockrings missing,bentorbrokenspacers,studs,missingclampsorlugnuts.

•Checkconditionoftires:properlyinated,noseriouscuts,bulges,tread wearoranysignsofmisalignment;valvestemsnottouchingwheels,rimsor brakedrums;valvecapsinplaceandnoobjectsstuckbetweenthewheels.

•Checkthatbothtiresareofsametype,forexample,notmixedradialand biastypeandthattheircircumferencesarematched.

•Checkwheelbearingandhub:noobviousleakingonoutsideorinsidewheel.

84PRE-TRIPINSPECTIONANDDAILY MAINTENANCE

Suspension

•Conditionofsprings(leaforair),springhangers,shacklesandU-bolts.

•Axlealignment.

•Conditionoftorquerodarms.

•Ifequippedwithslidingaxles,checkpositionandalignment.Lookfor damaged,wornormissingparts,alllockspresent,fullyinplaceandlocked.

•Flexibleairtubingnotcracked,cut,crimpedorotherwisedamaged.Itshould besecuredagainsttangling,draggingandchang.

Brakes

•Conditionofbrakedrums.Withbrakesreleased,lookforanoticeablegap betweenlininganddrum.(Thischeckcannotbemadeifdustcoversare inplace.)

•Conditionofbrakehoses:checkforanychang.

•Checkbrakechambermountingboltsandbrackets.

•Checkslackadjustersandchamberpushrodtravel.Withbrakesappliedor released,lookforconspicuouslydifferentpositionsoftheslackadjusters.

•Checkspringbrakes.

Step14:LeftSideofTrailerArea

LandingGearorDollyArea

•Fullyraised;nomissingordamagedparts.

•Crankhandlepresentandsecured.

•Ifpoweroperated,noair/hydraulicleaks.

SpareWheel(s)

•Sparewheelsecurelymountedinrackwithnodamagetorack.

•Tireandwheelconditionadequateforaspare:propersize,properlyinated.

LightsandReectors

•Trailersideclearancelights:clean,operatingandpropercolor.

•Reectorscleanandpropercolor.

PRE-TRIPINSPECTIONANDDAILY

MAINTENANCE85

FrameandBody

•Frameandcrossmembersnotbent,cracked,damagedormissing.

•Properplacarding.

•Bodypartsnotdamagedormissing.

BeforeLeavingtheParkingArea

•Removechocksfromthewheels.

•T esttrailerhook-upbyslowlypullingwhileapplyingthetrailerbrakeswith thetrailerbrakehandcontrolvalve.

•T esttheservicebrakesbeforeleavingtheparkingarea.

•T estparkingbrakesbystoppingona20%gradeandapplyingtheparking brakes.Theparkingbrakesshallholdthecombinedvehicleandtrailerwithout moving.

86OPERATION

NewVehicleBreak-In

Toensuremanyyearsofreliable,trouble-freeoperation,thefollowingbreak-in proceduresarerecommended:

Note:Oilchange,lterchangeandchassislubricationarenolongerrequiredat the3,000-milevehiclebreak-ininterval.

RefertothepreventivemaintenanceschedulesoutlinedintheMaintenance andLubricationManual(21394653)forrecommendedlubricationchange

intervalsforthefollowingitems:

•Gearoils(transmission,rearaxlecarrier[s],frontdriveaxlecarrier,transfer case,ywheelPTO)

•Engineoil

•Oillters

•Fuellters

•Coolantconditioner

Note:Itisimportantthatcomponentsbelledwithlubricantsmeetingthe specicationsasgivenintheMaintenanceandLubricationManual(21394653)

Note:Whencheckingoillevels,thevehiclemustbeparkedonlevelground,and theunitsatnormaloperatingtemperature.Componentsmustbelledtothecorrect level.DONOTOVERFILL.

Note:Oilandlterchangeintervalsinthismanualpertaintocomponentsbuiltby MackTrucks,Inc.Forinformationconcerningoilandoillterchangeintervalsfor vendorcomponents,refertothespecicvendorcomponentserviceliterature.

DuringtheFirst5000Kilometers(3000Miles)

•Aftertherst200km(125miles),retorquethewheelnutsusinganaccurately calibratedtorquewrench.Recheckthistorqueagainafter800km(500miles).

•Checkoilandcoolantlevelsfrequently .

•Checkbrakeandclutchadjustmentsperrecommendedmaintenance schedule,andadjustasneeded.

•Observetheinstrumentsoften,andshutdowntheengineattherstsignof anyabnormalreadings.

•Reportallleaks,loosefasteners,unusualnoises,etc.,totheservice representativeatthenearestMackdealershipsotheycanbecheckedand corrected.

OPERATION87

•Checkthespringcliptorque(U-bolts).(OnREYCOsuspensions,alsocheck equalizernuttorque.)

•OnchassisequippedwithAIRTEK™frontaxleairsuspensions,retorque theU-bolts.

•ChecktheU-bolttorqueontheMACKairsuspensionattheendoftherst 1600km(1000miles).

AftertheFirst5000Kilometers(3000Miles)orBefore6400Kilometers (4000Miles)orBefore3to4Months

•Retorquethespringclip(U-bolts).(OnREYCOsuspensions,alsoretorque theequalizernut.)

Note:OnchassisequippedwithAIRTEK™frontaxleairsuspensions,checkthe torqueofthefrontaxleU-boltsat24000kilometers(15,000miles).

AttheFirstAInspectionInterval

•Checkfrontandrearaxlealignmentandadjustifthealignmentisoutof specications.

•Checksteeringknuckletoaxlebeamclearance.

Althoughthisquality-builtvehiclehasbeeninspected,lubricatedandadjusted attheMACKTrucksAssemblyPlant,anoccasionalair,oilorcoolantleakmay develop.Quickactiontocorrecttheseminoritemswillpreventamajorrepair later.TakethevehicletothenearestMACKservicecenterassoonasany abnormalconditionbecomesevident.

InitialValveAdjustmentIntervals

RefertotheMaintenanceandLubricationManual(21394653)fordetailed informationconcerningtheInitialV alveAdjustmentIntervalalsoseepage223.

88OPERATION

WINDSHIELDWASHERRESERVOIR

Asshowninthedrawingbelow,thewindshieldwasherreservoirislocated onthedriver-sidebackofthecab.

C0029606

OPERATION89

CABTILTOPERATION

DANGER

Beforeattemptingtotiltthecab,becertaintotakethefollowingsteps:

•Parkonalevelsurface.

•Applytheparkingbrake.

•PlacethegearshiftleverinNEUTRALposition.

•Shutofftheengine.

•Securealllooseitemswithinthecab.

•Closethecabdoors.

Thecabismountedonthechassisframebytwofronthingesandtworear cablocks.Thisarrangementallowsthecabtotiltforwardtoamaximumof60 degrees,exposingtheenginecompartmentforeasyaccessibility.

Thecabtiltsystemusesonehydrauliccylinder.Itincorporatesinternalsafety valveswhichlockupautomaticallyifthecabmovestoorapidlyineither direction.

Thehydraulicuidpressureimbalanceforcesthecheckvalvestoseat, holdingthecabinahydraulicallylockedposition.Ifthissituationoccurs, operatethepumpintheoppositedirectiontoopenthecheckvalves.The systemwillthenbereturnedtonormaloperation.

MACK LEU Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual