MACK CHU, CXU, GU, TD Service Manual

Driver'sHandbook

Addendum

Addendum,MACKConventional(Build

DateAugust2012)

Foreword

ThisaddendumdetailstheupdatesfortheMACKConventional
Operator'sManual,andappliestovehiclesbuiltAugust2012andlater.
Pleasekeepthisaddenduminthevehicleatalltimes.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.

MACKTrucksInc.shouldbeinformedimmediatelyifyoubelievethat
thevehiclehasadefectthatcouldcauseacrash,injuryordeath.

MackTrucks,Inc.

Greensboro,NCUSA

Ordernumber:PV776-

©2012MackTrucks,Inc.,Greensboro,NCUSA

Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionofMackTrucks,Inc.

Contents

Information.....................................................................................................................1

Addendum....................................................................................................................1

Operator'sManualUpdatesforMACKConventional(BuildDateAugust2012)......1

CenterConsole(DayCabOnly)..................................................................................2

DeadPedal(FootRest)................................................................................................3

AmbientFloorLighting...............................................................................................4

CabAuxiliary(Sleeper)HV ACBlowerSwitch..........................................................5

Self-CancellingTurnSignalLever..............................................................................6

ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.......7

MACKPOWERLEASH™ENGINEBRAKE......................................................7

EngineBrakeSwitch................................................................................................8

HowtheEngineBrakeisActivated.........................................................................9

CruiseControlwiththeMACKPowerLeash™EngineBrake...............................10

MACKPowerLeash™EngineBrakewithoutCruiseControl................................12

OverFlatTerrain......................................................................................................13

DescendingaGrade.................................................................................................14

OnSlipperyRoadSurfaces......................................................................................16

SafetyInformation

IMPORTANT:Beforedrivingthisvehicle,becertainthatyouhavereadand
thatyoufullyunderstandeachandeverystepofthedrivingandhandling
informationinthismanual.Becertainthatyoufullyunderstandandfollowall
safetywarnings.

ITISIMPORT ANTTHA TTHEFOLLOWINGINFORMATIONBEREAD,
UNDERSTOODANDAL W AYSFOLLOWED.

Thefollowingtypesofadvisoriesareusedthroughoutthismanual:

DANGER

Dangerindicatesanunsafepracticethat
couldresultinseriouspersonalinjury
ordeath.Adangeradvisorybanneris
inwhitetypeonablackbackground
withablackborder.

CAUTION

Cautionindicatesanunsafepracticethat
couldresultindamagetotheproduct.
Acautionadvisoryisinblacktypeona

whitebackgroundwithablackborder.

WARNING

Warningindicatesanunsafepractice
thatcouldresultinpersonalinjury.A
warningadvisorybannerisinblack
typeonagraybackgroundwithablack
border.

Note:Noteindicatesaprocedure,practice,orconditionthatmustbefollowedinorder
forthevehicleorcomponenttofunctioninthemannerintended.

Information1

Addendum

Operator'sManualUpdatesforMACKConventional
(BuildDateAugust2012)

ThisaddendumdetailstheupdatesfortheMACKConventionalOperator'sManual
thatappliestovehiclesbuiltAugust2012andlater.Pleasekeepthisaddendumin
thevehicleatalltimes.

2Information

CenterConsole(DayCabOnly)

TheCenterconsolehasseveralfeatures,a12Vpowersupplylocatedatthebottomof
theconsole,a12Vlightinside,mapnettingontheface,andthehardtopthatactsasa
writingsurfacewithamaximumloadcapacityof45Kg(100lb).Theconsolecanbe
removedandreplacedwiththecurrentrearwalldispatchbox.

W8073352

Information3

DeadPedal(FootRest)

Thedeadpedal(footrest)islocatedonthelefthandsideoftheoorinthedrivers
footwell.

W8073381

4Information

AmbientFloorLighting

Theambientlightingisin3locations,driverfootwell,andthecenterandpassenger
sideoftheconsole.Theswitchwillbelocatedonthelowerpanelbelowthemain
lightswitch.Theswitchisa3positionswitch,withthepositionslistedbelow:

1st.“OFF”position

2nd.Driverfootwellonly

3rd.Entirecaboorarea

Thelightingcolorfortheambientlightingissoftredtoavoidaffectingnightvision.

1Switch

2AmbientLamps

W2073628

Information5

CabAuxiliary(Sleeper)HVACBlowerSwitch

Thecabauxiliary(Sleeper)HV ACblowerswitchislocatedinpanelDofthedash
(refertoinstrumentandcontrols)inoperator’shandbook.Theswitchisintherocker
panelbayabovetheenginecover.Inorderfortherearsleepercontrolstooperate,
thecabauxiliary(Sleeper)HV ACblowerswitchmustbeturnedonattherocker
panel.ThefunctionistointerrupttheauxiliaryHV ACblowercircuit.Thisallows
thesleepertobepre-warmedorpre-cooledfromthecab.So,forexample,adriver
maypresetthesleeperHV ACtoactivateA/Catmediumblowerspeed.Thenhecan
interruptthecircuitfromthedriverseat.About15minbeforehewantstopullover
torest,hecanactivatethesleeperAuxHV ACcircuittopre-coolthesleeper.This
switchisstandardwithallsleeperswithauxHV AC(Mack60”&70”sleepers).The
switchiconisshownbelow.

W8074020

6Information

Self-CancellingTurnSignalLever

Theturnsignalleverislocatedonthesteeringcolumnandisself-cancelling.It
performsanumberoffunctions,includingswitchingfromhighandlowbeams,
turnsignalswitchandthehazardswitch.Theturnsignalswitchcanbeused
forcourtesyashingofmarkerlightsandfortheashingofhighbeams.

W3075524

1.ClearanceFlash3.PullforHazard(Red)

2.HeadlampFlash

4.ClusterDisplayControl

Information7

ONTHEROADWITHTHEMACKPOWERLEASH™
ENGINEBRAKE

Ifyouarenotfamiliarwiththeuseandoperationofaheavy-dutydiesel
enginebrake,itisessentialthatyoureadthefollowingsectioncarefully.Itis
veryimportantthatyoutakethetimetogainexperiencewithyourMACK
PowerLeash™EngineBrakeingooddrivingconditions,beforeusingitin
difcultorhazardousdrivingconditions,suchassteepdescentsorslippery
roads.Ofcourse,thereisnosubstitutefordrivertrainingbyaqualied
specialist.

Thefollowinginformationisintendedasaguidelinetosafeandappropriate
useoftheMACKPowerLeash™EngineBrake.Itisdifculttodescribe
everypossibledrivingcondition.Certaincircumstancesmayrequireamore
conservativeapproachthanwillbedescribed.Whenencounteringanynew
drivingrouteorsituation,erronthesideofcaution.

MACKPOWERLEASH™ENGINEBRAKE

MACKMP7,MP8andMP10enginesmaybeequippedwithPowerLeash.These
enginesareidentiedontheengineinformationsticker.

IfyourvehicleisequippedwiththeMACKPowerLeash™EngineBrake,itis
importantthatyoutakethetimetobecomefamiliarwithyourenginebrakebefore
puttingitintooperation.

WARNING

Operationofanyvehicleonwetorslipperyroadsrequiresextremecaution.
BecausetheMACKPowerLeash™EngineBrakeconvertstheenginetoa
retardingdevice,itshouldNOTbeusedonwetorslipperyroadsifthevehicle
hasasingledrivingaxleorifithastandemdrivingaxlesthatarelightly
loaded.Useofanenginebrakeundertheseconditionscancausethevehicleto
skidoracombinationvehicletojackknife.

8Information

EngineBrakeSwitch

EngineBrakeSwitch

1OFF:Noenginebrakingpower

2Medium:Halfenginebrakingpower

3High:Fullenginebrakingpower

W8074176

ControlSwitch

TooperatethevehiclewithoutMACKPowerLeash™EngineBrakeactive,leavethe
dash-mountedswitchintheOFFposition.

TheMack3position(Off-Med-Hi)isusedtoturntheenginebrakefunctiononor
off,andtosetmaximumbrakingeffort(50%or100%).IftheControlSwitchis
on,theenginebrakewillactivateautomaticallywhenthethrottlepedalisreleased
and/orat0%.

CAUTION

TheV-MAC®systempreventsengine
brakeactivationiftheoiltemperatureis
below55°C(131°F).Thedrivershould
bealerttothefactthattheengine
brakewillnotfunctionuntilsufcient
warm-uptimehaselapsed,regardless
ofthedashswitchsetting.

Information9

HowtheEngineBrakeisActivated

WhentheMACKPowerLeash™EngineBrakeis"enabled"(switchineither
MediumorHIGHposition),yourengineV-MAC®electroniccontrolsystem
commandsenginebrakepower(MACKPowerLeash™EngineBrake"active")
onlywhenthefollowingconditionsaretrue:

•Thefoot-operatedengineacceleratorpedalisnotdepressed.

•Theclutchpedalisnotdepressed(manualshifttransmissionsonly).

•Theenginespeedisatleast900rpm.

•Vehiclemustbeingear.

•Vehiclespeedshouldbegreaterthan8km/h(5mph)

IftheMACKPowerLeash™EngineBrakeisactive,theenginebrakewill
automaticallybedeactivatedbydepressingeithertheacceleratorortheclutch,
oriftheenginespeeddropsbelow900rpm.AssoonasalloftheMACK
PowerLeash™EngineBrake"active"conditionsareagaintrue(takingyour
footofftheaccelerator,forexample),theMACKPowerLeash™EngineBrake
willagainbeactivated.InordertodisabletheMACKPowerLeash™Engine
Brake,simplyreturnthedash-mountedcontrolswitchtotheOFFposition.

DANGER

TheMACKPowerLeash™EngineBrakeshouldneverbeconsideredasubstitute
forthevehicleservicebrakes.Theservicebrakesshouldalwaysbemaintainedin
goodworkingorder,andshouldalwaysbeviewedastheprimaryvehicleslowing
system.Servicebrakesarealwaysusedtobringthevehicletoacompletestop.

10Information

CruiseControlwiththeMACKPowerLeash™
EngineBrake

WhentheMACKPowerLeash™EngineBrakeisenabledatthesametime
yourV-MAC®cruisecontrolisinuse,theMACKPowerLeash™EngineBrake
automaticallyactivatesengageanddisengageabovethecruisecontrolset
speedwhennecessarytoslowthevehicletothecruisesetpointspeed.

IftheSetSwitchisnotdepressed,thisisthesamefunctionalityastoday's
non-mDRIVEormDRIVEAutoModevehicles,ora3mphoverdefault.

UsingtheSET+andSET-buttons,thedefaultengagementspeedcannowbe
raisedorloweredtosuitindividualdriverneeds.Therangelimitationonthis
parameteris1to10mphoverthecruisecontrolsetMPH.

W4060025

TheMACKPowerLeash™EngineBrake‘sabilitytocontrolmaximumvehicle
speedislimitedtotheselectedretardingpoweroftheenginebrake.Ifthe
enginebrakedash-mountedcontrolswitchissettotheMediumposition,only
halfoftheavailablebrakingpowerisused.Ifthedash-mountedcontrolswitch
issettotheHIGHposition,thecruisecontrolinvokesfullenginebrakepower.

Note:WhentheMACK®PowerLeash+™EngineBrakeisactiveandthe
transmissionisshiftinggears,therewillbeamomentaryinterruptionofthebraking
torque.Thismayresultinatemporaryincreaseofvehiclespeediftravellingdownhill.
Theoperatorwillexperiencethesamemomentarylossofenginebrakingasis
experiencedwhendownshiftingaconventionalmanualtransmission.

Note:DeactivatingthecruisecontrolfunctiondoesnotdisabletheMACK
PowerLeash™EngineBrake.

Information11

TheMACKPowerLeash™EngineBrakemaybeactivatedordeactivatedby
othervehiclesystemssuchasABSandHeadwaycontrolsystems.Referto
theliteratureconcerningthesesystemsforadditionalinformation.

Note:AnexceptionexistsifthevehicleisequippedwithaBendixActiveCruise
Control&CollisionWarningsystem.Ifthevehicleisequippedwiththesefeaturesthe
Bendixsystemwillassumefuelingandbrakingcontrolwheninactivecruisecontrol
moderegardlessofthepowerleashcontrolswitchsettingtomaintainfollowing
interval.

12Information

MACKPowerLeash™EngineBrakewithoutCruise
Control

Thisisasimplied2switchPowerLeash+enginebrakecontrol.ThestandardMack
3position'Off-Med-Hi'CONTROLSwitch,locatedtotheleft,iscarriedoverfrom
non-mDRIVEvehiclesandisusedtoturntheenginebrakefunctiononoroff,andto
setmaximumbrakingeffort(50%or100%).

IftheControlSwitchison,theenginebrakewillactivateautomaticallywhenthe
throttlepedalisreleasedand/orat0%.Thisthenfunctionsidenticallytothecurrent
Macknon-mDRIVEsystem.

Thesecond(totheright)switchistheSETSwitch.TheSETSwitchisamomentary
(pressandrelease)switchwithSET+intheupperportionandSET-inthelowerpart
oftheswitch.Whendepressed,theSetSwitchsetsatargetdownhillsetspeed,and
brakingeffortwillthenvaryfrom0%to100%toholdthatsetspeed.Again,no
fuelinginput,nothrottleinput.Ifforexamplethecurrentvehiclespeedgoesabove
thesetspeed,thePowerLeash+willbefullon.

IfcurrentvehiclespeedgoesbelowthesetMPH,thePowerLeashoutputwillbe
0%,Atthesetspeed,thebrakingoutputwillbevariable(0-100%).PressSET+to
furtherraisethetargetdownhillspeed,andSET-tolowerit,andCo-Pilotwilldisplay
thecurrentsettings.

Note:Thesetspeedisretainedinmemoryevenifthethrottleisreapplied.Itcanonly
beerasedbyturningtheenginebrakeCONTROLSwitchoff,cyclingtheignitionkey,
orautomaticallywhenvehiclespeeddropsbelow30mph.Onceerased,theengine
brakewillthenautomaticallyactivatewheneverthrottleinputis0%(throttlereleased).

IftheSetSwitchisnotusedatall,thereisnochangeinenginebrakefunctionvs
traditionalMackvehicles.IftheSetSwitchisused,PowerLeash+functionslikea
downhillcruisecontrol,lettingthedriversethisdownhillspeed.T ypicallythedriver
wantsthesetspeedretaineduntilitisresetoruntilhighwaydrivingends,hencethe
30mph“offramp”reset.

W8074176

ControlSwitch

SetSwitch

W8074177

Information13

OverFlatTerrain

TheLOWpowerpositionislikelyadequatetocontrolvehiclespeedin
situationswheretheroadwayisrelativelyatorhasmodestlygradedrolling
hills,andiftotalvehicleweightislight.

C0029331

1.Off

3.High

2.Low

Asgradesandvehicleweightincrease,itwillbenecessarytousetheHIGH
position.

W2074482

1.Off

3.High

2.Low

14Information

DescendingaGrade

DANGER

TheMACKPowerLeash™EngineBrakeassistsyouinestablishingfaster
downhilldescentspeedsthaninasimilarlyconguredandloadedvehiclewithout
anenginebrake;nevertheless,evenwithanenginebrake,therearelimitstothe
maximumvehiclespeedatwhichyoucantravelondownhillgradesandstill
keepyourvehiclesafelyundercontrol.Alwaysapproachthesesituationswith
caution,andgaintheexperiencenecessaryforeachgradeanddrivingcondition
todeterminetheappropriatedownhilldescentspeed.

Foracertainvehicleandloadcondition,a"controlspeed"maybeestablished
foragivendescent.Thecontrolspeedisthevehiclespeedatwhichthe
retardingforcesofairdrag,rollingresistanceandenginebrakepowerare
equallybalancedbythenaturalforceofgravitythatcausesthevehicleto
acceleratedownthehill,resultinginasteady,controlledvehiclespeed.The
additionalvehicleslowingpowerofferedbytheMACKPowerLeash™Engine
Brakeallowsthedrivertodescendthehillinahighergearthannormal(ata
fastercontrolspeed),withoutoverspeedingtheengine.

Forexample,considerthatyouaredescendingagradewithaspecicvehicle
andanassumedtotalvehicleweight.Y ouwillndthatwithoutanMACK
PowerLeash™EngineBrake,youmustdescendthisgradeinthirdgearto
maintainasteady10mphat2,000enginerpm,withouttheneedtoapply
theservicebrakes.

C0029333

1.DescentSpeedwithoutMACKPowerLeash™EngineBrake

Information15

SwitchtheMACKPowerLeash™EngineBraketotheHIGHposition,andnow
itispossibletodescendthesamegradeinsixthgeartomaintainasteady
35mphat2,000enginerpm.

CAUTION

Themaximumallowableenginespeedislistedonthewarninglabelonthesun
visor.DoNOTexceed2,300rpm.

C0029334

1.DescentSpeedwithMACKPowerLeash™EngineBrake

Inanygearselectionhigherthansixthgear(inthisexample),itwouldbe
necessarytooccasionallyapplytheservicebrakestomaintainasafevehicle
speedandtoavoidoverspeedingtheengine.

DANGER

Aswithanyvehicle,regularandexcessiveapplicationoftheservicebrakes
duringadownhilldescentcanleadtoabrakeliningoverheatcondition,resulting
inaverydangerouslossofservicebrakeretardingcapability.

Note:Thepreviousguresapplyonlytothishypotheticalexample.Specicvehicle
controlspeedsandenginespeedsforagivendescentaredependentupontheactual
vehicleandenginecongurations,thegrossweightofthevehicle,andthepercent
gradeoftheroad.

16Information

OnSlipperyRoadSurfaces

Aswithmanyaspectsofoperatingaheavy-dutyvehicle,specialcareshould
betakenwhenusingtheMACKPowerLeash™EngineBrakeonslipperyroad
surfaces.Thepotentialforunpredictablelossofvehicletractionisaserious
concern;insomesituationstheenginebrakeshouldnotbeusedatall.

Asalways,approachuntesteddrivingconditionswithcaution.Avoiduseofthe
MACKPowerLeash™EngineBrakeinthesesituationsuntilyouhavegained
someexperienceundernormaldrivingconditions.

Asarule,makesurethatthevehicleisdemonstratinggoodtractabilitywiththe
enginebrakeoffbeforecheckingfortractabilitywiththeenginebrakeenabled.
Then,providedtrafcconditionsaresafefor"testing"tractability,switchthe
MACKPowerLeash™EngineBraketotheLOWposition.Ifthevehicleshows
anysignsoflossofcontrol(ABSactivationorvehicleswerving,forexample),
immediatelyswitchtheenginebrakebacktotheOFFposition.

1.Off

2.Low

C0029332

3.High

Information17

OnlyifthevehicledemonstratesgoodcontrolintheLOWposition(again,only
insafedrivingconditions)shouldyoutestintheHIGHposition,ifdesired.
ReturntotheLOWpositionandproceedwithcautionifthereisanysignof
lossvehiclecontrol.

Note:Alwaysmonitorvehicletractabilityinslipperyroadconditions,andmake
adjustmentstotheMACKPowerLeash™EngineBrakeswitchpositionandvehicle
speedasnecessary .AlwaystesttheLOWpowerpositionsettingbeforemovingto
theHIGHposition.

YourMACKPowerLeash™EngineBrakeandABScontrolsystemsare
designedtoworktogetherforoptimizedvehiclecontrol.Theenginebrake
functionwillbeinterruptedbrieyintheeventofawheellock.

CAUTION

DonotenabletheMACKPowerLeash™EngineBrakeduringbobtailoperations,
orwhenoperatingonslipperyroadswithanemptyorlightlyloadedtrailer .

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PV776-English8.2012©MackTrucks,Inc.,2012