2010 Mack TerraPro Series (LEU Series) Operator's Manual

Mack LEU Series
®
Mack TerraPro Series
® TM
Mack TerraPro Series
® TM
(LEU Series) (LEU Series)
21394654
21394654 © Mack Trucks, Inc. 2010 21394654

Printed in U.S.A. April 2010
Foreword
This manual contains information concerning the operation and
function of the Mack Link System. The information in this manual
applies to vehicles built April 2010 and later. Please keep this manual
in the vehicle at all times.
Note: Illustrations in this manual are used for reference only and may
differ slightly from the actual vehicle. However, key components
addressed in this document are represented as accurately as possible.
The National Highway Traffic Safety Administration (NHTSA) and
Mack Trucks Inc., should be informed immediately if you
believe that the vehicle has a defect that could cause a crash, injury
or death.
Contact NHTSA by calling the Auto Safety Hotline at 1 (888)
327-4236, by writing to NHTSA, U.S. Department of Transportation,
Washington, DC 20590, by TTY at 1 (800) 424-9153, or visit their
website at www.nhtsa.dot.gov.
Mack Truck, Inc.

Greensboro, NC USA
Order number: PV776-21394654
©2010 Mack Trucks, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced,

stored in retrieval system, or transmitted in any forms by any means,
electronic, mechanical, photocopying, recording or otherwise, without
the prior written permission of Mack Trucks, Inc.
Contents
INTRODUCTION............................................................................................................1
TO THE OWNER..........................................................................................................1
In Appreciation ..........................................................................................................1
About This Handbook................................................................................................2
THE VEHICLE..............................................................................................................3
Basic Configuration ...................................................................................................3
Vehicle Management and Control System (V-MAC®).............................................3
COMPONENT IDENTIFICATION ..............................................................................4
VIN Locations............................................................................................................4
Engine Identification..................................................................................................5
Engine Information Plate ...........................................................................................6
Clean Idle Engines .....................................................................................................7
Transmission Identification........................................................................................8
WARRANTY INFORMATION ..................................................................................10
Air Brake System.....................................................................................................10
ENGINE GASEOUS EMISSION CONTROL SYSTEMS ....................................10
Emissions Control System Warranty .......................................................................11
ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY.............13
FEDERAL EMISSION REQUIREMENTS............................................................14
EMISSION CONTROL SYSTEMS WARRANTY — CALIFORNIA..................14
Emissions Control System Warranty .......................................................................16
SERVICE LITERATURE ............................................................................................20
MACK Class 8 –Components Service Manual .......................................................20
MACK Class 8 – Custom Collated Service Manual on CD ....................................20
CUSTOMER SERVICE ..............................................................................................21
Call 1-800-866-1177 for MACK OneCall™ ...........................................................21
Questions and Complaints .......................................................................................21
Addresses .................................................................................................................22
Additional Assistance ..............................................................................................22
REPORTING SAFETY DEFECTS.............................................................................24
United States ............................................................................................................24
Canada......................................................................................................................24
Mexico .....................................................................................................................24
EVENT DATA RECORDING DEVICES...................................................................25
SAFETY INFORMATION ...........................................................................................26
SAFETY STATEMENT ..............................................................................................26
CERTIFICATION LABELS........................................................................................28
Safety Certification Label ........................................................................................28
ADVISORY LABELS .................................................................................................30
Advisory Label Locations (On Vehicle) ..................................................................30
CAB ENTRY/EXIT .....................................................................................................39
Three-Limb Contact.................................................................................................39
Driver Side ...............................................................................................................41
Passenger Side .........................................................................................................43
SAFETY TIPS FOR COLD WEATHER OPERATION .............................................44
Driver Visibility .......................................................................................................44
Cab Door Seals and Key Locks ...............................................................................45
Outside Mirror Heater..............................................................................................45
Air Horn Snow Shield..............................................................................................46
Fire Extinguisher (Optional) ....................................................................................46
INSTRUMENTS AND CONTROLS ...........................................................................47
CAB INTERIOR — LEFT ..........................................................................................47
CAB INTERIOR — RIGHT .......................................................................................48
INSTRUMENT PANEL ..............................................................................................49
Tell-Tales..................................................................................................................49
Panel Arrangement...................................................................................................50
INSTRUMENT PANEL GAUGE LAYOUT ..............................................................51
Panels A, B, C and D ...............................................................................................52
Panel E .....................................................................................................................53
Panel F .....................................................................................................................54
DPF INHIBIT ROAD SPEED LIMITING (RSL)...................................................62
CAB CLIMATE CONTROL .......................................................................................68
LIGHT CONTROL PANEL ........................................................................................69
STEERING COLUMN................................................................................................70
Combination Starter and Electrical Switch..............................................................70
MISCELLANEOUS CONTROLS ..............................................................................71
Dome Light ..............................................................................................................71
Air Horn ...................................................................................................................71
Fresh Air Vent ..........................................................................................................72
Accessory Power Outlets .........................................................................................72
PRE-TRIP INSPECTION AND DAILY MAINTENANCE......................................73
PRE-TRIP ....................................................................................................................73
Pre-Trip Inspection Quick List ................................................................................73
OPERATION..................................................................................................................86
.....................................................................................................................................86
New Vehicle Break-In..............................................................................................86
WINDSHIELD WASHER RESERVOIR ....................................................................88
CAB TILT OPERATION.............................................................................................89
Tilting the Cab .........................................................................................................90
Lowering the Cab.....................................................................................................92
Bleeding the Cab Tilt System ..................................................................................93
DOORS ........................................................................................................................94
Opening the Cab Door .............................................................................................94
Locking the Cab Door..............................................................................................94
Right-Side (Folding) Door.......................................................................................94
Folding the Door ......................................................................................................97
Unfolding the Door ................................................................................................100
SEAT BELTS .............................................................................................................102
Seat Belt Operation ................................................................................................102
Fastening Seat Belt ................................................................................................102
RIGHT-SIDE RESTRAINT ......................................................................................105
SEAT ADJUSTMENT...............................................................................................106
Right-Side Folding Seat.........................................................................................106
Air Seat ..................................................................................................................107
MIRROR SYSTEMS.................................................................................................109
Moto Mirror System ..............................................................................................109
MACK ENGINE INFORMATION ...........................................................................112
Precautions and Warnings......................................................................................112
Engine Model Designations...................................................................................113
CRUISE CONTROL OPERATION ..........................................................................114
Speed Control Switches .........................................................................................114
Disengaging Cruise Control...................................................................................115
MACK POWERLEASH™ ENGINE BRAKE (IF EQUIPPED)..............................116
Engine Brake Switch..............................................................................................117
How the Engine Brake is Activated.......................................................................117
Cruise Control with the MACK PowerLeash™ Engine Brake .............................118
ON THE ROAD WITH THE MACK POWERLEASH™ ENGINE BRAKE .........119
Over Flat Terrain....................................................................................................119
Descending a Grade ...............................................................................................120
On Slippery Road Surfaces....................................................................................122
BRAKE OPERATION...............................................................................................124
Air Brake System...................................................................................................124
Automatic Slack Adjusters ....................................................................................125
Parking Brake System............................................................................................125
Parking Brake Operation........................................................................................126
Parking ...................................................................................................................126
Anti-Lock Brake System (ABS) ............................................................................127
Automatic Traction Control (ATC) (If Equipped) .................................................130
Work Brake System ...............................................................................................131
GOOD DRIVING HABITS.......................................................................................133
Weight Ratings.......................................................................................................133
Instruments.............................................................................................................133
Shutting Down the Engine .....................................................................................133
General Observation ..............................................................................................133
STARTING THE VEHICLE .....................................................................................134
General Information...............................................................................................134
Push Button Starters...............................................................................................134
Air Starters .............................................................................................................135
Engine Warm-Up ...................................................................................................138
Engine Idling..........................................................................................................138
Shutting Down the Engine .....................................................................................139
COLD WEATHER OPERATION .............................................................................141
Cold Weather Starting Tips....................................................................................141
Engine Block Heaters ............................................................................................142
MOVING THE VEHICLE — GENERAL INFORMATION ...................................143
Braking...................................................................................................................143
Engine Temperature ...............................................................................................143
TRANSMISSION SHIFTING INSTRUCTIONS.....................................................145
Status Lights ..........................................................................................................148
Transmission Module Location .............................................................................149
AXLES.......................................................................................................................150
Rear Axles Other Than MACK .............................................................................150
MACK Rear Axles.................................................................................................150
Engaging the Power Divider Lockout....................................................................151
Extended Idling and Aftertreatment System Conditioning .......................................154
Mack, US10 Emissions Solution .................................................................................155
DIESEL PARTICULATE FILTERS .........................................................................155
Exhaust Aftertreatment System .................................................................................158
Safety Information .................................................................................................159
Exhaust Aftertreatment System Components and ................................................160
Selective Catalytic Reduction (SCR) ....................................................................160
Diesel Exhaust Fluid (DEF)...................................................................................162
Aftertreatment Diesel Particulate Filter (DPF) ......................................................165
Aftertreatment Control Module (ACM).................................................................166
Exhaust Aftertreatment System ............................................................................166
Driver Warnings and On Board Diagnostics (OBD) .............................................172
On Board Diagnostics (OBD)................................................................................172
Instrument Cluster..................................................................................................173
Malfunction Indicator Lamp (MIL) .......................................................................174
Aftertreatment DEF Tank Level - Driver Warning & Inducement........................175
Aftertreatment DEF Quality - Driver Warning & Inducement ..............................176
Misfilling Diesel or Aftertreatment DEF Tanks.....................................................177
SCR Tampering - Driver Warning & Inducement .................................................178
Warranty and Maintenance ....................................................................................179
Exhaust Aftertreatment System Maintenance........................................................179
Engine Maintenance Intervals................................................................................179
MAINTENANCE AND LUBRICATION..................................................................180
MAINTENANCE INTRODUCTION .......................................................................180
TURBOCHARGER...................................................................................................181
CLEANING YOUR VEHICLE.................................................................................182
Exterior Washing ...................................................................................................182
Cab and Hood ........................................................................................................184
Chassis ...................................................................................................................184
Cab Interior ............................................................................................................184
Waxing ...................................................................................................................185
Polishing ................................................................................................................185
Winter Warnings ....................................................................................................185
TOWING ...................................................................................................................186
ENGINE OIL LEVEL CHECK.................................................................................188
Power Steering Reservoir ......................................................................................189
FUEL TANK..............................................................................................................190
Fuel Tank Cap ........................................................................................................190
FUELING ..................................................................................................................191
BioDiesel................................................................................................................192
B5 Approval For MACK US 2010 Certified Products ..........................................192
COOLING SYSTEM.................................................................................................194
Coolant Level Check..............................................................................................194
Draining the Cooling System.................................................................................195
Refilling the Cooling System .................................................................................195
Protecting the Cooling System ..............................................................................196
Cooling System Maintenance ................................................................................197
Accessory Drive Belt Routing ...............................................................................198
HEADLIGHTS ..........................................................................................................199
Bulb Replacement..................................................................................................199
WHEELS ...................................................................................................................199
Wheel Inspection ...................................................................................................199
Tires .......................................................................................................................200
BATTERY..................................................................................................................203
Jump-Starting Engine.............................................................................................203
ELECTRICAL ...........................................................................................................205
Circuit Breaker and Relay Panels ..........................................................................205
Electrical Grease ....................................................................................................209
Circuit Protection Charts........................................................................................210
METRIC CONVERSIONS.........................................................................................212
METRIC CONVERSIONS .......................................................................................212
Safety Information
IMPORTANT: Before driving this
vehicle, be certain that you have read DANGER
and that you fully understand each and
every step of the driving and handling Danger indicates an unsafe practice that
information in this manual. Be certain could result in serious personal injury
that you fully understand and follow all or death. A danger advisory banner is
safety warnings. in white type on a black background
with a black border.
IT IS IMPORTANT THAT THE
FOLLOWING INFORMATION BE
READ, UNDERSTOOD AND ALWAYS
FOLLOWED. WARNING
The following types of advisories are used Warning indicates an unsafe practice
throughout this manual: that could result in personal injury. A
warning advisory banner is in black
type on a gray background with a black
border.
CAUTION
Caution indicates an unsafe practice that
could result in damage to the product.
A caution advisory is in black type on a
white background with a black border.
Note: Note indicates a procedure, practice,

or condition that must be followed in order
for the vehicle or component to function
in the manner intended.
INTRODUCTION 1
TO THE OWNER
In Appreciation
Thank you for buying a MackK® vehicle. With proper care and maintenance,
your new Mack® TerraPro™ LEU model will help you gain a competitive edge
with its fuel-efficient drivetrain combinations, low maintenance, extended
service intervals and, eventually, good resale value.
The Mack® TerraPro™ LEU model is available for a wide range of
applications. Because of this versatility, drivetrains and components vary and
operating instructions may differ from one model to another. While every
effort has been made to cover all current arrangements, do not hesitate to
consult your MACK distributor if a question arises. Honest, personal service
is standard with every MACK sale.
CAUTION
Mack Trucks, Inc. would like to point out the important role that the driver plays in
the life of the vehicle. Only trained and informed drivers should operate this vehicle.
We, at Mack Trucks, Inc., hope that you will be happy with your new Mack®
TerraPro™ LEU model, and that you see many years of trouble-free driving.
This vehicle was built to conform to all federal standards and regulations
applicable at the time of manufacture.
2 INTRODUCTION
About This Handbook

This handbook is referred to as the Mack® TerraPro™ LEU Series Operator’s
Handbook. It covers all Mack® TerraPro™ LEU models. Its identification
number is 21394654. Keep this handbook with the vehicle at all times to
ensure that each owner and/or operator will have access to all pertinent
information relating to the operation and handling of this vehicle.
This handbook was prepared to provide the driver with all relevant information
concerning the daily operation of this vehicle. Please read it thoroughly;
pay particular attention to advisory labels that have been included to draw
attention to important issues of operator safety and overall performance.
Information and illustrations in this handbook are based on the latest
production usage at the time of printing and are subject to change without
prior notice.
Note: Basic maintenance and lubrication procedures are found in this manual
beginning with “MAINTENANCE INTRODUCTION”, page 180. For further
information, refer to the Maintenance and Lubrication Manual (21394653). Other
important information can be found in the Emission Control Systems for MACK
Diesel Engine Manual (21351488).
INTRODUCTION 3
THE VEHICLE
Basic Configuration
The Mack® TerraPro™ LEU model has a low-entry, cab-forward-style
operators compartment. One-step entry and dual steering/braking
arrangements make it a very popular and practical vehicle for refuse
management companies.
Vehicle Management and Control System

(V-MAC®)
The Vehicle Management and Control System (V-MAC) is an electronic
control system that manages engine and vehicle functions. In addition, the
DataMax™ portion of V-MAC monitors and stores a variety of information (i.e.,
maintenance schedules, overspeed logs, fault tables, trip summaries).
For a complete description of the V-MAC IV system, refer to the applicable
V-MAC® Operator’s Guide, which is supplied with the vehicle.
Additional information concerning service, diagnostics, programming and
vendor equipment interface application is available from the Mack Trucks, Inc.
Service Publications Department. Contact your local MACK dealer for details.
WARNING
Never cut into the V-MAC system wire harness to power additional equipment. If
such equipment is to be installed, contact your MACK dealer for assistance.
4 INTRODUCTION
COMPONENT IDENTIFICATION
Locate the following serial numbers and write them in the boxes provided
next to each illustration.
VIN Locations
The Vehicle Identification Number (VIN) is displayed in two locations (a frame
rail stamping and a label). The 17-digit VIN must be identical in both locations.
The VIN frame stamping is located on the right outside frame rail and the
left inside frame rail.
C0029554
The VIN label is located on the inside door frame below the driver seat.
C0028941
INTRODUCTION 5
Engine Identification
On the MACK MP engines, the engine serial number is stamped on the left
side of the engine block, below the inlet manifold.
C0028943
6 INTRODUCTION
Engine Information Plate

In compliance with Federal and California emission requirements, an
engine information label is affixed to all MACK diesel engines. This label,
which is located on the cylinder head cover at the front of the engine, gives
basic engine identification information (engine model, serial number, etc.),
advertised horsepower at rated speed, emissions regulations to which the
engine conforms and inlet and exhaust valve lash settings. Examples of the
49 state EPA approved, and 50 state EPA and California approved engine
identification labels are given below.
W2040455
Engine Identification Label - 49 State EPA Approved Engine

without California "Clean Idle"
W2040456
Engine Identification Label - 50 State EPA Approved Engine

with California "Clean Idle"
INTRODUCTION 7
Clean Idle Engines

The California Air Resources Board (ARB) requires that 2008 and later model
year vehicles be equipped with engines having tamper-resistant software
which limits the time at which the engine can idle at speeds above low idle
(550–700 rpm). At speeds above low idle, and without a PTO engaged, idle
time will be limited to five minutes, after which the engine will revert back
to low idle. Vehicles equipped with a Clean Idle engine are identified by a
label which is affixed to the lower portion of the driver’s side door on cab-over
models (LEU).
W2056289
Clean Idle Engine Label

8 INTRODUCTION
Transmission Identification
The Allison RDS and HS transmission identification plate is located on the
rear right side of the main case, near the lower end.
C0029555
The MACK carrier assembly serial number is located on the front right side
of the housing.
C0028950
The Eaton® Spicer® rear axle serial number is located on the rear of the
axle housing toward the carrier.
C0028951
INTRODUCTION 9
The Eaton® Spicer® carrier assembly serial number is located on the left
side of the forward carrier, and the top of the rear carrier.
C0028952
The MERITOR rear axle identification tag is located on the left or right rear of
the rear axle housing, next to the carrier.
C0028953
The MERITOR carrier assembly serial number is located on the left side of
the forward carrier, and the top of the rear carrier.
C0028954
10 INTRODUCTION
WARRANTY INFORMATION
This chassis is equipped with a US’10 emission compliant engine and an
exhaust aftertreatment system (Diesel Particulate Filter). Use of Ultra Low
Sulfur Diesel (ULSD) fuel and EO-O Premium Plus (or VDS-4) specification
high performance diesel engine oil is required in this vehicle.
Note: Use of improper or unapproved fuel or engine oil will void the engine and
aftertreatment system warranty.
Air Brake System

The MACK Standard Vehicle Warranty applies to the air brake system, as
set forth in the Warranty, but only if the air brake system has not been
subjected to unauthorized additions, deletions or modifications. If any such
unauthorized additions, deletions or modifications are performed, Mack
Trucks, Inc. disclaims any and all liability for any loss or damage arising out of
a malfunction of the air brake system.
The air brake system was designed and built to conform to all applicable
federal motor vehicle safety standards in effect at the time of manufacture.
Tractor air systems are designed for operation as a tractor only, and truck air
systems are designed to be operated as a truck only. If a tractor is going to be
converted for operation as a truck, the air brake system must be reconfigured
to that of a truck. Conversely, if a truck is going to be converted for operation
as a tractor, the air brake system must be reconfigured to that of a tractor.
Consult your local MACK distributor for additional information.
If any unauthorized additions, deletions or modifications are made to any
portion of the air brake system which is required by Federal Motor Vehicle
Safety Standards, Mack Trucks, Inc. makes no representation as to conformity
with the Standards.
For complete warranty information, refer to the Pedigreed Protection Plan
provided with each vehicle.
ENGINE GASEOUS EMISSION CONTROL

SYSTEMS
WARRANTY MAINTENANCE
Note: For emission control systems
information on engines other than MACK,
refer to the engine vendor’s publication
INTRODUCTION 11
ENGINE GASEOUS EMISSION CONTROL SYSTEMS

WARRANTY
Mack Trucks, Inc. warrants the Emission The repair or replacement of defective
Control Systems on each new Mack parts will be made without charge for
diesel engine in a new Mack Truck to the cost of parts and if repairs are made
comply with all United States Federal at an authorized Mack Trucks, Inc.
and Canadian emissions regulations dealership, there will be no charge for
applicable at the time of manufacture of labor. Mack Trucks, Inc.’s obligation
the engine, and to be free from defects under this warranty is limited to the repair
in material and workmanship under or replacement, at Mack Trucks, Inc.’s
normal use and service up to 60 months, option, of any part(s) of the Emission
or 160934 km (100,000 miles), which Control Systems of such engine and/or
ever occurs first, provided that all Mack vehicle found to be defective upon
Trucks, Inc. maintenance requirements examination by Mack Trucks, Inc. and
are followed as described in this manual. provided that such part(s) were returned to
All warranty periods are calculated from Mack Trucks, Inc. or its nearest authorized
the date-in-service of the new vehicle. Dealer within a reasonable period of time.
Qualifications and Limitations:

Note: Not covered by the Emissions • Inconvenience, loss of use of the
Control Systems Warranty: vehicle, commercial loss of any
• Malfunctions caused by misuse, kind including, but not limited to,
improper adjustments, modification, consequential or incidental damages
alteration, tampering, disconnection, • Any vehicle in which the odometer
improper or inadequate maintenance has been altered or damaged so that
and use of improper diesel fuel or DEF. mileage cannot be readily determined.
• Damage resulting from accident, acts
of nature or other events beyond the
control of Mack Trucks, Inc.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR
OTHERWISE, EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED
TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
Emissions Control System Warranty

The following engine components are covered by the supplemental emissions control
system warranty policy as required by the Federal code of emission regulations.
1 Turbocharger Assembly • CAC Hoses

• VGT Actuator 3 Engine Control Module (ECM)
2 Charge Air Cooler 4 Injectors
• CAC Pipes (Air inlet to/from CAC)
12 INTRODUCTION
5 Engine and Vehicle Wire harness ( • Aftertreatment DPF Intake

repair to circuits related to Emissions Temperature Sensor
Warrantable Components ) • Aftertreatment DPF Outlet
6 Exhaust Gas Recirculation (EGR) Temperature Sensor
Mixer • Aftertreatment DPF Differential
7 EGR Cooler Pressure Sensor
8 EGR Valve and EGR Valve Control • Aftertreament Doser Air Supply
9 EGR Pipes - Engine Exhaust Manifold Regulator (if applicable), Supply
to EGR Cooler Lines, and Fittings
10 EGR Pipes - EGR Cooler to Inlet B. Thermal Regeneration Unit (TRU)
Manifold • Aftertreatment DPF Combustion
11 Crankcase Breather Air Control Valve
12 Crankcase Separator • Aftertreatment DPF Combustion
Air Valve
13 Crankcase Tubing and Hoses before
Separator • Aftertreatment DPF Atomization
Module
14 Aftertreatment Wiring Harness
15 After treatment Control Module (ACM)
• Aftertreatment DPF Ignition Coil
16 Aftertreatment Diesel Particulate Filter

• Aftertreatment DPF Fuel Control
Valve
(DPF) Assembly
A. Aftertreatment DPF Assembly
• Aftertreatment DPF Ignition
Electrode
with Aftertreatment Diesel Oxidation
Catalyst (DOC) • Nozzle
• Aftertreatment Doser
• Engine Exhaust Gas Temperature
(EGT) Sensor
• Diffuser Pipe (Aftertreatment Fuel
• Aftertreatment DPF Intake
Doser Mounting)
Temperature Sensor
• Fuel lines to Aftertreatment Fuel
• Aftertreatment DPF Outlet
Doser
Temperature Sensor
• Aftertreatment Fuel Shutoff Valve
• Aftertreatment DPF Spark Assist
• Aftertreatment Fuel Pressure Sensor Flame Temperature Sensor
• Discharge Recirculation Valve • Aftertreatment DPF Differential
(DRV) (Heat Mode) Pressure Sensor
• Discharge Recirculation Valve 17 Sensors:
(DRV) Solenoid
• Crankshaft Position (CKP)
• Engine Turbocharger Compressor
• Camshaft Position (CMP)
Bypass Actuator (Heat Mode)
• Engine Coolant Temperature (ECT)
Bypass Actuator Solenoid • Intake Manifold Air Temperature
• Engine Exhaust Gas Temperature • Intake Manifold Pressure (IMP)
(EGT) Sensor • EGR Temperature
INTRODUCTION 13
• Aftertreatment Outlet NOx • Aftertreatment DEF Tank Heater

• Aftertreatment Intake NOx • Aftertreatment DEF Tank Heater
• EGR Differential Pressure Valve
• Ambient Air Temperature (AAT) • Aftertreatment DEF Tank

Temperature Sensor
18 SCR
• Aftertreatment DEF Level Sensor
• Aftertreatment Selective Catalytic
• Aftertreatment DEF Heated Lines
Reduction (SCR) Catalyst
• Aftertreatment Diesel Exhaust Fluid 19. Instrument Cluster (Repair of
microprocessor , OBD MIL, Real Time
(DEF) Pump
Clock, Aftertreatment DEF Tank Gauge
• Aftertreatment DEF Dosing and, Aftertreatment DEF Tank Low Level
Absolute Pressure Sensor Indicator)
• Aftertreatment DEF Return 20. Exhaust Gas Piping (from
Valve Turbocharger to Aftertreatment System )
• Aftertreatment DEF Dosing Valve 21. Data Link Connector (DLC)
• Aftertreatment DEF Tank
Heater/Sender
ENGINE GASEOUS EMISSIONS CONTROL

SYSTEM WARRANTY
The emission warranty for the diesel is considered normal maintenance and not
particulate filter (DPF) and SCR System covered by the emission warranty.
covers defects in workmanship only.
Note: In response to customer requests,
Normal maintenance, such as cleaning
ash from the filter at regular maintenance Mack Trucks, Inc. may build vehicles with
intervals and cleaning the aftertreatment engines supplied by other manufacturers.
fuel injector on Diesel oxidation catalyst In these cases, each engine manufacturer
(DOC) DPF systems, is not covered by through its service organization, is
the emission warranty. With the Thermal responsible for emission control systems
regenerator DPF system, cleaning the warranty on all parts of the engine
ignition electrodes and fuel injection
nozzle at the regular maintenance intervals assembly, as furnished.
14 INTRODUCTION
FEDERAL EMISSION REQUIREMENTS

This section covers the requirement of the be reasonable and necessary to assure the
United States Clean Air Act which states: proper functioning of emission control
“The manufacturer shall furnish with devices and systems. ”This section also
each new motor vehicle or motor vehicle covers the requirements of the emissions
engine such written instructions for the regulations promulgated under the Motor
maintenance and use of the vehicle or Vehicle Safety Act in Canada.
engine by the ultimate purchaser as may
TAMPERING WITH GASEOUS EMISSION CONTROL SYSTEMS
PROHIBITED
The Federal Clean Air Act prohibits the trading motor vehicles or motor vehicle
removal or rendering inoperative of any engines following its sale and delivery
device or element of design installed on or to the ultimate purchaser, or
in a motor vehicle or motor vehicle engine
in compliance with Federal Emission 4 Any person who operates a fleet of
Regulations by: motor vehicles following its sale and
1 Any person prior to its sale and delivery delivery to the ultimate purchaser.
to the ultimate purchaser, or Note: For specifics of the prohibited
2 Any manufacturer or distributor after vehicle/engine modifications refer to
its sale and delivery to the ultimate the Mack Trucks, Inc. Body Builders
purchaser, or documentation .
3 Any person engaged in the business of

repairing, servicing, selling, leasing, or
EMISSION CONTROL SYSTEMS WARRANTY —

CALIFORNIA
The California Air Resources Board and system, turbocharger assembly, electronic
Mack Trucks, Inc. are pleased to explain control module and other emission-related
the California emission control system assemblies.
warranty on your new motor vehicle Where a warrantable condition exists,
engine. In California, new motor vehicle Mack Trucks, Inc. will repair your engine
engines must be designed, built and at no cost to you including diagnosis,
equipped to meet the State’s stringent parts, and labor.
anti-smog standards. Mack Trucks, Inc. MANUFACTURER’S WARRANTY
must warrant the emission control system COVERAGE:
on your engine for the period of time listed If an emission-related part of your engine
below provided there has been no abuse, is defective, the part will be repaired or
neglect, or improper maintenance of your replaced by Mack Trucks, Inc. This is
engine. your emission control system DEFECTS
Your emission control system may WARRANTY.
include parts such as the fuel-injection
INTRODUCTION 15
OWNER’S WARRANTY RESPONSIBILITIES:

As the motor vehicle engine owner, you in the State of California) Mack Trucks,
are responsible for the performance of Inc. warrants the Emission Control
the required maintenance listed in this Systems on each new MACK diesel
manual. Mack Trucks, Inc. recommends engine in a new MACK truck to comply
that you retain all receipts covering with all State of California emissions
maintenance of your vehicle, but Mack regulations applicable at the time of
Trucks, Inc. cannot deny warranty solely manufacture of the engine, and to be free
for the lack of receipts or for your failure from defects in material and workmanship
to ensure the performance of all scheduled under normal use and service up to
maintenance listed in other manuals which 60 months, or 100,000 miles, or 3,000
were supplied with your vehicle. engine operating hours, whichever occurs
You are responsible for presenting first, provided that all Mack Trucks,
your motor vehicle engine to a MACK Inc. maintenance requirements are
dealer as soon as a problem exists. The followed as described in this manual. All
warranty repairs should be completed warranty periods are calculated from the
in a reasonable amount of time, not to date-in-service of the new vehicle. The
exceed 30 days. As the motor vehicle repair or replacement of defective parts
engine owner, you should also be aware will be made without charge for the cost
that Mack Trucks, Inc. may deny you of parts and, if repairs are made at an
warranty coverage if your vehicle or a authorized Mack Trucks, Inc. dealership,
part has failed due to abuse, neglect, there will be no charge for labor.
improper maintenance, or unapproved Mack Trucks, Inc.’s obligation under
modifications. this warranty is limited to the repair
If you have any questions regarding or replacement, at Mack Trucks, Inc.’s
your warranty rights and responsibilities, option, of any part(s) of Emission Control
you should contact the Mack Trucks, Systems of such engine and/or vehicle
Inc. Warranty Activities P.O.Box 26259, found to be defective upon examination by
Greensboro, NC 27402, or the California Mack Trucks, Inc. and provided that such
Air Resources Board at 9480 Telstar part(s) were returned to Mack Trucks, Inc.
Avenue, El Monte, California 91731. or its nearest authorized Dealer within a
(Applicable only to vehicles and/or reasonable period of time.
engines certified for sale and registered
Qualifications and Limitations:
Not covered by the Emissions Control • Inconvenience, loss of use of the

Systems Warranty: vehicle, commercial loss of any
• Malfunctions caused by misuse, kind including, but not limited to,
improper adjustments, modification, consequential or incidental damages.
alteration, tampering, disconnection, • Any vehicle in which the odometer
improper or inadequate maintenance has been altered or damaged so that
and use of improper diesel fuel or DEF. mileage cannot be readily determined.
• Damage resulting from accident, acts
of nature or other events beyond the
control of Mack Trucks, Inc.
16 INTRODUCTION
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES

AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR
OTHERWISE, EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED
TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
Emissions Control System Warranty

The following engine components are covered by the supplemental emissions control
system warranty policy as required by the California code of regulations.
1 Turbocharger Assembly • Aftertreatment Doser

• VGT Actuator • Diffuser Pipe (Aftertreatment Fuel
2 Charge Air Cooler Doser Mounting)
• CAC Pipes (Air inlet to/from CAC) • Fuel lines to Aftertreatment Fuel
Doser
• CAC Hoses
3 Engine Control Module (ECM)
• Aftertreatment Fuel Shutoff Valve
4 Injectors
• Aftertreatment Fuel Pressure Sensor
5 Engine and Vehicle Wire harness

Bypass Actuator (Heat Mode)
(repair to circuits related to Emissions
Warrantable Components ) • Engine Turbocharger Compressor
Bypass Actuator Solenoid
6 Exhaust Gas Recirculation (EGR)
Mixer • Engine Exhaust Gas Temperature
(EGT) Sensor
7 EGR Cooler
8 EGR Valve and EGR Valve Control
• Aftertreatment DPF Intake
Temperature Sensor
9 EGR Pipes - Engine Exhaust Manifold
to EGR Cooler
Temperature Sensor
10 EGR Pipes - EGR Cooler to Inlet
Manifold
• Aftertreatment DPF Differential
Pressure Sensor
11 Crankcase Breather • Aftertreament Doser Air Supply
12 Crankcase Separator Regulator (if applicable), Supply
13 Crankcase Tubing and Hoses before Lines, and Fittings
Separator B. Thermal Regeneration Unit (TRU)
14 Aftertreatment Wiring Harness • Aftertreatment DPF Air Shutoff
15 After treatment Control Module (ACM) Valve
16 Aftertreatment Diesel Particulate Filter • Aftertreatment DPF Combustion
(DPF) Assembly Air Valve
A. Aftertreatment DPF Assembly • Aftertreatment DPF Atomization
with Aftertreatment Diesel Oxidation Module
Catalyst (DOC) • Aftertreatment DPF Ignition Coil
INTRODUCTION 17
• Aftertreatment DPF Fuel Control • Aftertreatment Selective Catalytic

Valve Reduction (SCR) Catalyst
• Aftertreatment DPF Ignition • Aftertreatment Diesel Exhaust Fluid
Electrode (DEF) Pump
• Nozzle • Aftertreatment DEF Dosing
• Engine Exhaust Gas Temperature Absolute Pressure Sensor
(EGT) Sensor • Aftertreatment DEF Return
• Aftertreatment DPF Intake Valve
Temperature Sensor • Aftertreatment DEF Dosing Valve
Temperature Sensor
• Aftertreatment DPF Spark Assist
Heater/Sender
Flame Temperature Sensor
• Aftertreatment DPF Differential • Aftertreatment DEF Tank Heater
Pressure Sensor • Aftertreatment DEF Tank Heater
17 Sensors: Valve
• Crankshaft Position (CKP) • Aftertreatment DEF Tank
Temperature Sensor
• Camshaft Position (CMP)
• Engine Coolant Temperature (ECT) • Aftertreatment DEF Level Sensor
• Intake Manifold Air Temperature • Aftertreatment DEF Heated Lines

• Intake Manifold Pressure (IMP) 19. Instrument Cluster (Repair of
microprocessor , OBD MIL, Real Time
• EGR Temperature
Clock, Aftertreatment DEF Tank Gauge
• Aftertreatment Outlet NOx and, Aftertreatment DEF Tank Low Level
• Aftertreatment Intake NOx Indicator)
• EGR Differential Pressure 20. Exhaust Gas Piping (from
• Ambient Air Temperature (AAT) Turbocharger to Aftertreatment System )
18 SCR 21. Data Link Connector (DLC)
18 INTRODUCTION
ENGINE GASEOUS EMISSION CONTROL SYSTEMS

WARRANTY — Continued
The emission warranty for the diesel establishment, or by the owner, using any
particulate filter (DPF) and SCR System replacement part, within the limitations
covers defects in workmanship only. of paragraphs 3 and 4 in this section. An
Normal maintenance, such as cleaning emergency condition exists under this
ash from the filter at regular maintenance
intervals and cleaning the aftertreatment section if, after 30 days, repairs have
fuel injector on Diesel oxidation catalyst not been completed or parts are not yet
(DOC) DPF systems, is not covered by available. MACK will reimburse the
the emission warranty. With the Thermal owner for such repairs that are covered
regenerator DPF system, cleaning the under this warranty, including diagnosis,
ignition electrodes and fuel injection not to exceed MACK’s suggested retail
nozzle at the regular maintenance intervals
price for parts replaced and labor charges
is considered normal maintenance and not
covered by the emission warranty. based on MACK’s recommended time
allowance and geographically appropriate
Note: In response to customer requests, hourly labor rate. Replaced parts and paid
Mack Trucks, Inc. may build vehicles with invoices must be presented at a MACK
engines supplied by other manufacturers. facility as a condition of reimbursement for
In these cases, each engine manufacturer emergency repairs performed elsewhere.
through its service organization, is
responsible for emission control systems
warranty on all parts of the engine CAUTION
assembly, as furnished.
In the event that damage results from
unauthorized adjustments to any
CAUTION emission control system components,
as evidenced by settings other than as
Any unauthorized adjustments to the specified, or broken fastener seals, the
emission control components can cause cost of repairing such damage WILL
severe damage to the engine. NOT BE COVERED under warranty
1. Repairs by MACK Dealers, 3. Repairs by Non-MACK Facilities

Sub-Dealers and Service Dealers Owners may elect to have maintenance,
Repairs covered by the California replacement, or repair of emission control
Emission Control Systems Warranty will systems performed by any repair facility,
be performed by any authorized MACK and may elect to use parts other than
repair facility at his place of business with MACK parts without invalidating the
no charge for parts and labor (including warranty on other components, but the
diagnosis), using MACK parts for any part cost of such service or parts will not be
of the emission control systems covered covered by MACK under its warranty.
by this warranty and found defective. 4. Use of Non-MACK Parts
2. In an Emergency Use of replacement parts which are not the
In an emergency, where an authorized equivalent of MACK parts may impair the
MACK facility is not available, repairs effectiveness of emission control systems.
may be performed at any available service If other than MACK parts are used, the
INTRODUCTION 19
owner should obtain assurances that such • Damage resulting from accident, acts
parts are warranted by their manufacturer of nature or other events beyond the
to be the equivalent of MACK parts control of Mack Trucks, Inc.
in performance and durability. MACK • Inconvenience, loss of use of the
assumes no liability under this warranty vehicle, commercial loss of any
with respect to parts other than MACK kind including, but not limited to,
parts; however, the use of non-MACK consequential or incidental damages.
parts does not invalidate the warranty on
other components unless non-MACK parts • Any vehicle in which the odometer
cause damage to warranted parts. has been altered or damaged so that
mileage cannot be readily determined.
5. Maintenance and Maintenance
Records 7. Customer Assistance
The vehicle owner is responsible for the MACK wishes to assure that the California
performance of all required maintenance Emission Control Systems Warranty is
specified in this manual. MACK will not properly administered. In the event that
deny a warranty claim solely because there owners do not receive the warranty service
is no record of maintenance; however, to which they believe they are entitled
MACK may deny a warranty claim if under the California Emission Control
failure to perform required maintenance Systems Warranty, they should contact
results in the failure of a warranted part. the nearest MACK Regional Office for
Receipts or other records covering the assistance. The address and telephone
performance of scheduled maintenance number for each Regional Office are
should be retained to answer questions in the MACK Directory of Sales, Parts
that may arise concerning maintenance. and Service Centers. Owners in need
Maintenance records should be transferred of additional assistance or information
to subsequent owners if the vehicle is sold. concerning the California Emission
Control Systems Warranty may also
6. Items Not Covered by the Emission contact:
Control Systems Warranty
Mack Trucks, Inc.
• Malfunctions caused by misuse, Warranty Activities

improper adjustments, modification, P.O. Box 26259
alteration, tampering, disconnection, Greensboro, NC 27402
improper or inadequate maintenance
and use of improper diesel fuel.
20 INTRODUCTION
SERVICE LITERATURE
The MACK Service Publications department offers a variety of service literature
(including individual service manuals) that can be ordered through any MACK
dealer or on the Mack Trucks, Inc. website at www.macktrucks.com.
Note: Mack Trucks, Inc. would like to emphasize the importance of proper service
and maintenance procedures. Service, repair and replacements must be performed by
certified, licensed mechanics in accordance with MACK standards.
MACK Class 8 –Components Service Manual

This multi-binder set contains service information covering all MACK
components (i.e., engines, transmissions, front and rear axles, cabs, fuel
systems, electrical systems).
Note: If your vehicle contains a number of non-MACK (vendor) components, the

Class 8 – Custom Collated Service Manual might be more appropriate.
MACK Class 8 – Custom Collated Service Manual

on CD
This tailor-made set provides complete service information for all components
in the specified vehicle (including both MACK and vendor service manuals).
When ordering a Class 8 – Custom Collated Service Manual or Class 8 –
Custom Collated Service Manual on CD , be sure to include the complete
Model-Serial number and General Sales Order (GSO) number.
INTRODUCTION 21
CUSTOMER SERVICE
Call 1-800-866-1177 for MACK OneCall™

The OneCall customer support system is a toll-free nationwide hotline that
operates 24 hours a day, seven days a week, including holidays. If you break
down on the road, simply call 1-800-866-1177. There is a staff of trained,
experienced technicians ready to help. They can help troubleshoot a problem
to get you back on the road, arrange to send roadside assistance or arrange
for towing to the nearest MACK dealership.
OneCall provides personalized service. The person who initially takes your
call will be the same person who sees that your situation is resolved quickly
and to your satisfaction. If a follow-up call is necessary, the same familiar
voice will be on the other end of the line.
OneCall technicians can also help you plan ahead to keep your operation
running efficiently by scheduling routine maintenance and lubrication service,
or by locating the nearest MACK dealership.
Questions and Complaints

Your satisfaction is our most important concern.
If questions or complaints arise, first discuss the matter with the service
manager at the MACK facility involved. If you are not satisfied with the
service manager’s response, contact the branch manager, principal or general
manager of the distributorship. If assistance is required at a service dealer,
contact the owner of the establishment.
If, for any reason, you need further assistance after dealing with the personnel
at a MACK subsidiary or distributor, contact the regional service manager at
the nearest MACK regional service office. The regional service manager has
the responsibility and the authority to recommend action in most cases and
(with the aid of relevant district service personnel) will make every effort to
conduct a fair review of the situation.
22 INTRODUCTION
Addresses
The addresses, telephone and fax numbers of the Mack Trucks, Inc. regional
offices are:
United States
Northeast Region – 7900 National Service Road., Mail: P.O. Box 26259,
Greensboro NC 27402 , TEL: (336) 291-9001
Southeast Region – 6768 Southlake Parkway, Morrow, GA 30260, TEL:
(770) 960-0511, FAX: (770) 960-0593
Central Region –900 S. Frontage Rd., Suite 100, Woodridge, IL 60517, TEL:
(630) 910-3330, FAX: (630) 910-3331
Southwestern and Western Regions – 5605 N. MacArthur Blvd., #550,
Mail: P.O. Box 165408, Irving, TX 75016-5408, TEL: (972) 518-1614, FAX:
(972) 550-0389
Canada
Executive Office – Mack Canada, Inc., 5600A Cancross Court, Mississauga,
ON L5R 3E9, TEL: (905) 366-3400, FAX: (905) 366-0165
Australia
Mack Trucks Australia Pty. Ltd., CNR Archerfield and Boundary Roads, Mail:
P.O. Box 364, Richlands, QLD 4077, Australia, TEL: 61-7-3853-3333, FAX:
61-7-3853-3392
International
7900 National Service Road., Mail: P.O. Box 26259, Greensboro NC 27402 ,
TEL: (336) 291-9001
Additional Assistance
If additional assistance is required, Mack Trucks, Inc. maintains a Customer
Service Department (staffed by experienced personnel) to aid customers who
need information or assistance not provided at the local or regional level.
The Customer Service Department phone number is (610) 709-3961.
When contacting the regional service offices or Customer Service Department,
provide the following information:
• Vehicle Identification Number (VIN) — This 17-digit number is typically located

on a label on the driver-side door latch post and behind the front axle on the
right, front frame rail.
INTRODUCTION 23
• Model and year of the vehicle

• Date that the vehicle was purchased and put into service
• Date(s) and mileage of repair(s)
• Dealer that sold and/or serviced the vehicle
• Description of unresolved service complaint or inquiry
• Summary of action taken to date (by the dealer and the regional service office)
• Names of individuals (if known) contacted at the dealer and the Mack Trucks, Inc.
regional service office.
24 INTRODUCTION
REPORTING SAFETY DEFECTS
United States
If you believe that your vehicle has a defect which could cause a crash, injury
or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA), in addition to notifying Mack Trucks, Inc.
If NHTSA receives similar complaints, it may open an investigation and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your distributor, or Mack Trucks, Inc.
To contact NHTSA, either call the U.S. Government’s Vehicle Safety
Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to
http://www.NHTSA.gov; or write to: Administrator, National Highway Traffic
Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590.
You can also obtain other information about motor vehicle safety from the
Vehicle Safety Hotline.
Canada
Canadian customers who wish to report a safety-related defect to Transport
Canada — Defect Investigations and Recalls, may telephone the toll free
hotline at 1-800-333-0510, or contact Transport Canada by mail at Transport
Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa ON K1A
0N5. For additional road safety information, please visit the Road Safety
website at http://www.tc.gc.ca/roadsafety/menu.htm.
Mexico
Volvo Trucks de Mexico, S.A. de C.V. should be informed immediately if you
believe the vehicle has a defect that could cause a vehicle accident, injury or
death. Contact Volvo Trucks de Mexico by calling 011-52-55-50-81-68-50
or by writing to: Volvo Trucks de Mexico, S.A. de C.V., Prol. Paseo de la
Reforma 600, 1er. Piso — 121, Col. Santa Fe Pena Blanca, C.P. 01210,
Mexico, D.F. Within Mexico, call 01 (800) 90 94 900.
INTRODUCTION 25
EVENT DATA RECORDING DEVICES

Your Mack vehicle is equipped with a device generally referred to as an "event
data recorder" or "EDR." Please note that while the term "event data recorder"
is typically used throughout the motor vehicle industry, not every EDR is the
same; i.e., they do not all record the same data elements. The EDR on your
MACK vehicle records vehicle speed, engine rpm, time and date, plus a
variety of pedal and switch positions, both before and after an "event." Sudden
vehicle deceleration or the occurrence of certain other vehicle operational
characteristics will define (trigger) an "event."
Optional equipment available for your MACK vehicle, such as the Eaton®
VORAD® Collision Warning System, may also provide event data recording
features.
If you have a question about your EDR, please contact your MACK dealer or
regional service office.
26 SAFETY INFORMATION
SAFETY STATEMENT
Mack Trucks, Inc. cannot anticipate every possible occurrence which may
involve a potential hazard. An accident can be avoided by recognizing
potentially hazardous situations before a dangerous situation occurs.
Correctly performed service procedures are critical for technician safety and
safe, reliable operation of the vehicle.
DANGER
Do not operate the engine in an enclosed area. All internal combustion engines
give off various fumes and gases while running. Inhalation of exhaust fumes can
cause death.
DANGER
Do not sit in a parked vehicle for any extended amount of time with the engine
running if there are leaks in the exhaust system. Exhaust fumes could leak into the
cab area and death can result. On a regular basis inspect the exhaust system for
leaks and repair any leakage.
DANGER
Driver attitude is the most important part of any effective vehicle safety system.
Mack Trucks, Inc. strongly encourages all drivers and passengers to use their seat
belts, drive defensively, remain alert and respect the speed limits. Many accidents
can also be avoided through regular vehicle maintenance.
DANGER
Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts,
driveshafts and other related rotating assemblies, can be very dangerous. Do not
service engine-driven components unless the engine is shut down. Always keep
body parts and loose clothing out of range of these powerful components to prevent
serious personal injury. Be aware of PTO engagement or nonengagement status.
Always disengage the PTO when not in use.
SAFETY INFORMATION 27
WARNING
Certain everyday procedures such as washing the vehicle and cleaning the
windshield can also be hazardous because of the vehicle’s height. Mack Trucks,
Inc. does NOT recommend climbing up on the vehicle to perform these operations.
Instead, stand on the ground and use brushes and squeegees mounted on extension
poles. When better access is necessary (for instance, when washing the cab roof),
use sturdy ladders held in place by someone on the ground.
WARNING
Secure loose objects. Loose objects in the cab or sleeper can be dangerous in a
sudden stop or on bad roads. Secure any appliance added to the vehicle, such as a
refrigerator or a radio.
WARNING
Keep clear of fan when engine is running. Fan may start to rotate at high speed
without warning.
CERTIFICATION LABELS
Safety Certification Label

National Highway Traffic Safety Administration (NHTSA) regulations require
affixing a certification label to all vehicles.
NHTSA regulations also require that the certification label be affixed to either
the hinge pillar, door latch post or the door edge that meets the door latch
post next to the driver seat. If none of these locations are practical, it may be
attached to the left side of the instrument panel or to an inward facing surface
of the driver-side door.
In compliance with NHTSA regulations, your Mack® vehicle has a safety
certification label affixed in one of the NHTSA locations listed above. This
label may be either an Incomplete Vehicle and/or Completed Vehicle label.
Both labels are described below.
Incomplete Vehicles
C0028955
A chassis-cab is an incomplete vehicle with a completed occupant

compartment that requires the addition of cargo-carrying, work-performing or
load-bearing components to perform its intended functions.
The chassis-cab manufacturer must affix a label to the incomplete vehicle in
one of the NHTSA locations listed above. This label provides the chassis-cab
date of manufacture, VIN and vehicle certification information.
Completed Vehicles
In addition to the label supplied by Mack Trucks, Inc. as the chassis-cab
manufacturer, a Completed Vehicle certification label, supplied by the body
manufacturer, is affixed in the same general location. This label provides
information pertaining to Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR), tire and rim information, etc.
On MACK-completed vehicles, this label contains the date of manufacture,
VIN, GVWR, GAWR, and tire and rim data. It is found in one of the NHTSA
locations listed above.
C0028956
ADVISORY LABELS
Throughout this book you will find paragraphs labeled Danger, Warning,
Caution, Note and Service Hint. Danger, Caution and Warning labels are
also found in various locations on the vehicle to alert drivers, operators and
service technicians to situations which can cause personal injury or equipment
damage. The labels shown are applicable to the Mack® TerraPro™ LEU
model chassis at the time of publication and are representative of what can be
typically found on a Mack® TerraPro™ LEU. (Your vehicle may not contain all
of the labels illustrated in this handbook.) These labels are for your benefit.
Please look through this section and note the labels, their locations and what
they explain. Be sure to replace any label that is damaged.
Advisory Label Locations (On Vehicle)

Labels Found on Chassis
C0029556
C0029557
C0029558
C0029559
Labels Found on Driver-Side Sun Visor
C0029560
Labels Found on Cowl (Near Ashtray)
C0029561
Labels Found on Instrument Panel
C0029017
C0029562
Eaton Controlled Traction Differential Label
C0029020
Labels Found on Fuel Tank
C0029021
Back Up Alarm (Optional)
Your chassis may be equipped with an optional back up alarm. If so, the
following label will appear inside the cab.
C0029022
C0029563
CAB ENTRY/EXIT
Three-Limb Contact
WARNING
When entering or exiting a cab, the driver and/or passenger must have at least
three limbs in contact with the vehicle or ground at all times. This means that a
minimum of two hands and one foot, or one hand and two feet must be in FIRM
contact with the vehicle or ground.
WARNING
When entering or exiting the cab, be aware of the condition of the steps and
handrails. Clean any fuel, oil or grease off of the steps before entering the cab.
During cold weather operation, ice and snow may accumulate and should be
cleaned off to prevent slipping.
During cold, wet conditions when ice, slush, or snow may accumulate on the
cab doorstep and other external surfaces, extra caution must be observed
when entering or exiting the cab.
WARNING
GUIDELINES FOR ENTERING AND EXITING TO AVOID SERIOUS
INJURY
• Face the cab when entering AND exiting.
• Place papers, coats, etc., in cab BEFORE entering. Take out AFTER exiting.
Keep hands free to grip handholds.
• Keep hands and shoes clean. Check hands and shoes for grease, mud, etc.,
BEFORE entering or exiting.
• Keep 3 limbs (2 hands and 1 foot or 1 hand and 2 feet) in FIRM contact with steps
and handholds at ALL times.
• Be sure of where you step and grab the handholds. Keep the areas clean.
• Be EXTRA careful in rainy, snowy, etc., weather.
• Do NOT jump from vehicle.
Note: The illustrations on the following pages are typical for purposes of emphasizing
a safe method for hand/foot placement and movement during cab entry/exit. Your
vehicle may not look exactly like the one pictured.
Note: The arrows in the illustrations are intended to show movement. Notice that
three-limb contact is maintained even when one foot, or one hand, is moving.
Driver Side
The following cab entry and exit procedures, along with the safety guidelines
outlined in Three-Limb Contact earlier in this section, should be used with
this MACK vehicle.
Entry
These entry procedures are illustrated on the following page:
1 With both feet firmly on the ground, grab the outside handhold with one hand and
grab the inside handhold with the other hand. Then raise one foot to the bottom
step. (See figure 1.)
2 Move hand [1] from the inside handhold to the steering wheel, then raise your
other foot to the cab floor. (See figure 2.)
3 Move hand [2] from the outside handhold to the steering wheel. (See figure 3.)
4 Bring the other foot inside the cab and sit down. (See figure 4.)
Exit
To exit, follow the illustrations in reverse order:
1 With both hands gripping the steering wheel, stand up and face the inside of the
cab. Move one foot to the bottom step. (See figure 4.)
2 Move one hand to the outside handhold and continue to grip the steering wheel
with the other hand. (See figure 3.)
3 With one foot firmly on the bottom step, lower the other foot to the ground. (See
figure 2.)
4 With both hands firmly gripping the handholds, lower the other foot to the ground.
(See figure 1.)
C0029564
Passenger Side
The following cab entry and exit procedures, along with the safety guidelines
outlined in the Three-Limb Contact section, should be used with this MACK
vehicle.
Entry
These entry procedures are illustrated on the following page:
1 Grab the handhold with one hand, and place the other hand on the steering wheel.
Do not use the folding door as a handhold. Raise one foot to the cab floor. (See
figure 1.)
2 While still gripping the handhold and the steering wheel, move the other foot into
the cab. (See figure 2.)
Exit
To exit, follow the illustrations in reverse order:
1 Grip the handhold with one hand, and the steering wheel with the other hand. Then
move one foot to the ground. (See figure 2.)
2 While still gripping the handhold and steering wheel, move the other foot to the
ground. (See figure 1.)
C0029565
SAFETY TIPS FOR COLD WEATHER OPERATION
Driver Visibility
Poor driver visibility is not only annoying, but extremely unsafe under any
circumstance. Without proper maintenance of visibility-related components,
adverse weather conditions such as rain, snow and frost can seriously reduce
visibility. Take time before winter arrives to check the following:
• Windshield Wipers
― Check windshield wiper operation and speeds.
― Inspect condition and travel of blades. Install new refills for any blades that are
cracked, brittle, torn, or coated with road oil along the wiping edge.
• Windshield Washers
― Check operation of windshield washer.
― Inspect system hoses and replace if brittle or worn.
― Inspect washer reservoir. Drain and flush if dirt particles are evident in washer
solution.
― Fill reservoir with commercially available non-freezing type washer fluid.
CAUTION
Do NOT fill reservoir with water only. Even though non-freezing type washer fluid
is recommended, do not attempt to clear the windshield of ice by activating the
windshield washer and wipers. Ice accumulations should be removed manually
by using a scraper.
• Heater/Defroster
― Check operation and blowers for speed control, noise and temperature.
― Inspect heater core for signs of corrosion and/or leakage.
― Check that the defroster blend door is operating correctly and that all ducting
is connected properly.
― Be sure that vents are not obstructed by debris or other objects.
Cab Door Seals and Key Locks

Hollow-core rubber weather seals around some cab doors may lose their
resilience in extremely cold temperatures (i.e., –40°C/–40°F and below).
Under these conditions, it may be necessary to drill holes to penetrate
the hollow core. This allows entrapped air to escape, thereby easing the
opening/closing of cab door(s).
Be sure to keep the key locks clean and dry to prevent occasional winter
freeze-up. Use of antifreeze lubricants is neither required nor recommended.
Outside Mirror Heater

In areas of frequent snowfall and ice, it may be beneficial to install heated
mirrors which will defrost and de-ice cab mirrors. Heated mirrors eliminate the
need to pull off the highway and stand on the roadside to scrape ice and snow
from the mirrors during winter driving conditions. Heated mirrors are available
either cab mounted or fender mounted.
C0029132
Air Horn Snow Shield

Installation of an air horn snow shield is recommended to prevent snow from
clogging the air horn bell (maintaining maximum sound output).
C0029133
Fire Extinguisher (Optional)

Your vehicle may be equipped with a fire extinguisher which is located inside
your cab. Check your fire extinguisher regularly to make sure it is fully charged.
INSTRUMENTS AND CONTROLS 47
CAB INTERIOR — LEFT
C0029566
1. Turn Signal, Hazard Switch and 3. Foot Pedals

HI/LO Beam
2. Instrument Panels
48 INSTRUMENTS AND CONTROLS
CAB INTERIOR — RIGHT
C0029567
1. Instrument Panels 3. Foot Pedals

2. Work Brake 4. Turn Signal, Hazard Switch and
HI/LO Beam
INSTRUMENT PANEL
Tell-Tales
A tell-tale is a display that indicates the actuation of a device, a correct or
defective condition, or a failure to function.
The operator should become familiar with these symbols in order to recognize
and react (if necessary) to the indicated condition. Tell-tale symbols are shown
in the instrument panel illustrations on the following pages.
Colors
To promote visual recognition internationally, specific colors for tell-tales
have been established. Unless governmental regulations (in the area where
the vehicle is to be used) or engineering directives specify otherwise, the
standard colors are:
• Blue – high-beam headlights/engine maintenance

• Flashing Green – turn signals
• Flashing Red – hazard condition involving the safety of personnel
• Steady Green – system in operation
• Steady Red – warning, immediate action required
• Amber – early warning, such as low fuel or Anti-Lock Brake System (ABS)
malfunction
Panel Arrangement
Your view from the driver seat should look something like the illustrations
shown. The layout is designed to provide the operator with a good view of the
gauges and controls (which are placed so they are within easy reach). The
instrument panel, as shown in the following drawing, is broken down into
several main sections. For easy identification we refer to them, from left to
right, as Panels A, B, C, D, E and F (where necessary).
Note: This section shows the instruments and controls available for this vehicle at the
time of publication. However, depending on options, your vehicle may not have all
the instruments and controls shown here, and they may not be in the same position.
INSTRUMENT PANEL GAUGE LAYOUT
W3056176
Panels A, B, C and D
W3056177
1. Coolant Temperature Gauge 8. DEF Gauge/Fuel Gauge

2. Tachometer 9. Air Pressure Gauge
3. Oil Pressure Gauge 10. Parking Brake Valve
4. Warning/Indicator Lamp Panel 11. Transmission Oil Temperature
Gauge
5. Speedometer/Odometer 12. Voltmeter
6. High Beam Indicator 13. Mode Button
7. Turn Signal Indicators 14. Hour Meter
Panel E
C0029589
15. CB Radio Auxiliary Hookup 25. Auxiliary Switch — Body Function

16. DPF Smart Switch (If Equipped) 26. Light Control Panel
17. Inter-Axle Power Divider Lockout 27. Combination Starter and Electrical
Switch (If Equipped) Switch
18. Telma Rear Axle Mounted 28. Right-Hand Operation Switch
Retarder (If Equipped)
19. Windshield Wiper/Washer Control 29. Moto-Mirror Switch (If Equipped)
Switch
20. Automatic Traction Control 30. Heated Mirror Switch (If
Switch/Heavy Mud/Snow Equipped)
21. Cab Climate Control Panel 31. Resume/Set Switch
22. Power Take-Off Control Switch (If 32. Speed Control Switch
Equipped)
23. Auxiliary Switch — Body Function 33. Cigar Lighter or Accessory Power
Outlet
24. Parking Brake Valve
Note: If equipped with Automatic Traction Control (ATC), the control switch will
be located on instrument panel E. Refer to “Automatic Traction Control (ATC) (If
Equipped)”, page 130 of the OPERATION section of this manual for ATC operation
and heavy mud/snow option.
Panel F
C0029590
34. Air Pressure Gauge 35. Speedometer/Odometer
1. Coolant Temperature Gauge — Indicates the temperature of the engine

coolant. The normal operating temperature for MACK MP7 engine is between
77°C and 107°C (170°F and 225°F). The driver will receive a warning if
coolant temperature reaches 223°F and engine shutdown will occur at 227°F
if the engine coolant temperature shut down option is enabled.
CAUTION
Coolant temperature must NOT exceed 107°C (225°F).
2. Tachometer — Indicates engine speed in revolutions per minute (RPM).

Tachometer readings should be used as a guide for shifting, as well as to
prevent engine damage due to overspeed. The blue band indicates the
optimum range for engine brake operation.
3. Oil Pressure Gauge — Indicates engine oil pressure. The normal
operating oil pressure for a MACK MP7 engine (at governed speed) is
between 275.8 and 620.5 kPa (40 and 90 psi). At idling speed, the oil pressure
should be between 275.8 and 413.9 kPa (40 and 60 psi).
Should the oil pressure drop suddenly from normal readings, stop the engine
immediately and determine the cause.
4. Warning/Indicator Lamp Panel – Items listed below from left to right and
top to bottom.
W3056178
Detail of Warning/Indicator Light Panel – LH

• Optional Tell-Tales
• Malfunction Indicator lamp (MIL) — MIL indicates government Regulation
On Board Diagnostics (OBD) faults. Lamp remains active after repair until
system operation confirms repair.
• Electronic Malfunction Indicator (Amber) — Illuminates when V-MAC®
detects an electronic malfunction. Refer to the appropriate V-MAC®
Operator’s Guide for details.
• Engine Shutdown Indicator (Red) — Indicates the occurrence of a
condition which requires that the engine be shut down (i.e., low water level,
low oil pressure or high water temperature). If the engine shutdown feature
is enabled, the operator has about 15 seconds after the light goes on to pull
to the side of the road before the engine shuts off. If the engine shutdown
feature is disabled, the indicator will function as a warning light but the engine
will not shut down.
• Aftertreatment DEF tank Low Level Indicator (DEF) — Illuminates when
the fluid level is low. It also Flashes when the level becomes critically low.
• Reverse Indicator — Indicates that the transmission is in Reverse.
• Low Air Pressure Warning Indicator — Indicates low air pressure in the air
brake system(s). This feature may also come with a buzzer.
• Parking Brake Indicator — Indicates that the parking brake is engaged.
• HEST Indicator (Amber) — The High Exhaust Temperature (HEST) indicator
is displayed when the exhaust temperature reaches 300°C (572°F) and the
regeneration process begins. When the regeneration process is completed,
the engine should be allowed to run until the HEST indicator shuts off.
During regeneration while the vehicle is moving, the HEST indicator will only
illuminate when vehicle speed is less than 8 kph (5 mph).
During a parked regeneration, the HEST indicator will turn off when
regeneration is complete and the exhaust temperature has returned to a
normal temperature.
C0029146
HEST Indicator
• Neutral Indicator — Indicates that the transmission is in Neutral.
• Anti-Lock Brake System (ABS) Indicator (Amber) — Indicates an ABS
malfunction. Also illuminates momentarily as a bulb check when the ignition
is turned on. If the light turns on and stays on, a malfunction is indicated. If
the light does not turn on when the ignition is turned on, the bulb and the
power source may be defective. For additional information on operating an
ABS-equipped vehicle, refer to “Anti-Lock Brake System (ABS)”, page 127,
in the OPERATION section.
Note: When an ABS malfunction is detected, anti-lock braking in the affected wheel
will be disabled and normal braking will return; the other wheels will retain anti-lock
braking.
• Automatic Traction Control (ATC) Indicator — Indicates that ATC is
operating.
• Aftertreatment DPF Regeneration Required Icon — Flashes when the
Diesel Particulate Filter is full or overfull and regeneration is needed. The
icon flashes when the filter is
• Check Transmission Warning Indicator (If Equipped) — Only present on
vehicles equipped with automatic transmission.
• Right-Hand Operation Indicator — Indicates that a right-hand drive mode

has been enabled.
• Maintenance Due Indicator — Indicates that a maintenance alert has been
issued (maintenance is due).
• Aftertreatment DPF Regeneration Inhibit Icon — Illuminates when the
inhibit switch is turned on. It will allow the driver to know that the switch is in a
inhibit position and a regeneration will not occur.
• Forced Neutral Indicator — Illuminates when PTO is engaged and the
truck is not moving.
• Fuel Filter Restriction (If Equipped)
• Air Filter Restriction (If Equipped)
• Predictive Oil Change (If Equipped)
• Engine Oil Level Indicator — If illuminated, immediately check the level of
your engine oil.
• Water in Fuel Indicator (If Equipped) — Illuminates when water
accumulates in the primary fuel filter sediment bowl. Stop the engine and
drain the fuel from the sediment bowl.
W3056183
Detail of Warning/Indicator Light Panel – RH

• Malfunction Indicator lamp (MIL )— MIL indicates government Regulation

On Board Diagnostics (OBD) faults. Lamp remains active after repair until
system operation confirms repair.
• Electronic Malfunction Indicator (Amber) — Illuminates when V-MAC®
detects an electronic malfunction. Refer to the appropriate V-MAC®
Operator’s Guide for details.
• Engine Shutdown Indicator (Red) — Indicates the occurrence of a
condition which requires that the engine be shut down (i.e., low water level,
low oil pressure or high water temperature). If the engine shutdown feature
is enabled, the operator has about 15 seconds after the light goes on to pull
to the side of the road before the engine shuts off. If the engine shutdown
feature is disabled, the indicator will function as a warning light but the engine
will not shut down.
• Aftertreatment DEF tank Low Level Indicator (DEF) — Illuminates when
the fluid level is low. It also Flashes when the level becomes critically low.
• Reverse Indicator — Indicates that the transmission is in Reverse.
• Low Air Pressure Warning Indicator — Indicates low air pressure in the air
brake system(s). This feature may also come with a buzzer.
• Parking Brake Indicator — Indicates that the parking brake is engaged.
• HEST Indicator (Amber) (If Equipped) — The High Exhaust Temperature
(HEST) indicator is displayed when the exhaust temperature reaches 300°C
(572°F) and the regeneration process begins. When the regeneration process
is completed, the engine should be allowed to run until the HEST indicator
shuts off.
• Neutral Indicator — Indicates that the transmission is in Neutral.
• Anti-Lock Brake System (ABS) Indicator (Amber) — Indicates an ABS
malfunction. Also illuminates momentarily as a bulb check when the ignition
is turned on. If the light turns on and stays on, a malfunction is indicated. If
the light does not turn on when the ignition is turned on, the bulb and the
power source may be defective. For additional information on operating an
ABS-equipped vehicle, refer to “Anti-Lock Brake System (ABS)”, page 127,
in the OPERATION section.
• Automatic Traction Control (ATC) Indicator — Indicates that ATC is
operating.
• Aftertreatment DPF Regeneration Required Icon — Illuminates when the

Diesel Particulate Filter is becoming full and regeneration is needed. The icon
flashes when the filter is full or overfull.
• Check Transmission Warning Indicator (If Equipped) — Only present on
vehicles equipped with automatic transmission.
• Right-Hand Operation Indicator — Indicates that a right-hand drive mode
has been enabled.
• Coolant Temperature Gauge — Indicates the temperature of the engine
coolant. The normal operating temperature for Mack engines is between 77°C
and 107°C (170°F and 225°F). The driver will receive a warning if coolant
temperature reaches 223°F and engine shutdown will occur at 227°F if the
engine coolant temperature shutdown option is enabled.
• Aftertreatment DPF Regeneration Inhibit Icon — Illuminates when the
inhibit switch is turned on. It will allow the driver to know that the switch is in a
inhibit position and a regeneration will not occur.
• Forced Neutral Indicator — Illuminates when PTO is engaged and the
truck is not moving.
Turn Signal Indicator LH — Flash green when the turn signals are activated.
High Beam Indicator (Blue) — Indicates that high beams are on.
Turn Signal Indicator RH — Flash green when the turn signals are activated.
• Engine Oil Level Indicator — If illuminated, immediately check the level of
your engine oil.
• Water in Fuel Indicator (If Equipped) — Illuminates when water
accumulates in the primary fuel filter sediment bowl. Stop the engine and
drain the fuel from the sediment bowl.
5. Speedometer/Odometer — Indicates road speed in miles and/or
kilometers per hour and total distance vehicle has traveled.
6. High Beam Indicator (Blue) — Indicates that high beams are on.
7. Turn Signal Indicators — Flash green when the turn signals are activated.
8. Fuel /DEF Gauge — Registers the fuel and DEF levels in the supply tank(s).
9. Air Pressure Gauge — Indicates the air pressure in the air brake
system(s). The normal operating air pressure is between 759 kPa (110 psi)
and 897 kPa (130 psi) in both air brake systems. If pressure drops below 75
psi (±5 psi) in either system, the warning buzzer and warning light will go
on. Determine the cause of failure before proceeding. Primary air pressure
is supplied to the rear brakes and is indicated by the green pointer on the
gauge. Secondary air pressure is supplied to the steering axle brakes and
indicated by the orange pointer.
10. Parking Brake Valve — Yellow diamond-shaped knob. Pull to apply.
Push to release. Applies parking brakes.
11. Transmission Oil Temperature Gauge — Indicates the temperature
of the automatic transmission oil. The normal operating range is between
71°C and 93°C (160°F and 200°F). If the transmission oil temperature
reaches 121°C (250°F), operation in the higher gears will be inhibited. If the
transmission overheats during normal operation, stop the vehicle and check
the transmission oil level. If both the transmission oil temperature gauge and
the engine coolant temperature gauge indicate a high temperature, check the
cooling system. If the cooling system appears to be functioning properly, shift
the transmission into Neutral, set the parking brakes, and run the engine
between 1200 and 1500 rpm. The engine and transmission should cool
sufficiently within two to three minutes. If the temperature does not drop to
operating range, the condition must be investigated and corrected before
continuing operation.
12. Voltmeter — Indicates the surface charge of the battery with the engine
NOT running (and the ignition ON). Indicates the condition of charging system
with the engine running.
The voltmeter can be useful as a diagnostic tool. During cranking, the reading
should not drop below 10 volts. Lower readings may indicate corroded
connections at the cranking motor or battery terminals, or discharged or
defective batteries.
13. Mode Button — Using this button will display diagnostic trouble code
information and trip distance in the odometer. When you press and hold down
this button, the display will go through a gauge self test. After the self test is
complete, diagnostic trouble code information will be displayed, by MID, in the
speedometer/odometer screen. When the first MID is displayed, push the
Mode button again to display the 1st diagnostic trouble code for this MID.
At the end of the diagnostic trouble code list for each MID, "CLEAR" will be
displayed. You have the option here to clear the codes for this MID. If you
choose to do so, press and hold the Mode button. Once the codes are cleared
for this MID, the next MID will be displayed.
By pressing this button once (NOT holding it down), information for Trip 1
distance will be displayed. Press and hold the Mode button to clear Trip 1
information.
By pressing this button twice, information for Trip 2 distance will be displayed.
Press and hold the Mode button to clear Trip 2 information.
14. Hour Meter — Indicates hours of engine operation. Hours of operation

should be used as a guide for certain engine or PTO maintenance operations.
15. CB Radio Auxiliary Hookup
16. DPF Smart Switch (If Equipped) — This is a three-position switch where
the middle position is neutral.
C0029592
1. Upper Position — Regeneration 3. Down Position — Inhibit Position

Position
2. Middle Position — Neutral Position
DPF INHIBIT ROAD SPEED LIMITING (RSL)

The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen)
position by the driver. If the DPF Smart Switch remains in the locked position,
the following vehicle speed limiting will occur:
1 Vehicle Moving. If vehicle is moving with the DPF Smart Switch in the locked
(DOWN) position, the vehicle speed will decrease down to 16 kph (10 mph) below
the current speed until the driver releases the switch back to the neutral (MIDDLE)
position.
2 Vehicle Stationary and then Moving. If the vehicle is stationary with the DPF
Smart Switch in the locked (DOWN) position and the driver then begins to move
the truck, the vehicle speed will be limited to 16 kph (10 mph) until the driver
releases the switch back to the neutral (MIDDLE) position.
17. Inter-Axle Power Divider Lockout Switch (If Equipped) — See

Inter-Axle Power Divider Lockout in the OPERATION section of this handbook
on .
C0029594
18. Telma Rear Axle Mounted Retarder Indicator Lamp (If Equipped) —
The Telma does not have a disable switch. It is always on and will operate
at different levels depending on application of service brake. The indicator
will show you the level you are retarding the vehicle: 20%, 40%, 60%, 80%
or 100%.
Note: The Telma retarder is disabled if there is an ABS event.
C0029217
Telma Retarder
19. Windshield Wiper/Washer Controls — Depress the ON/OFF button to

turn the windshield wipers on or off. Pull the button up to make the wipers
faster, push the button down to make the wipers slower. Depress the "WASH"
button to activate the washer fluid.
C0029595
20. Automatic Traction Control Switch/Heavy Mud/Snow — Activate for

increased traction control in heavy mud or snow. (See “Automatic Traction
Control (ATC) (If Equipped)”, page 130 in the OPERATION section of this
manual for more details.) When the operator presses the top of the rocker
switch, the heavy mud/snow function ATC indicator lamp blinks continuously.
The ATC lamp stops blinking when the ATC mode switch is pressed again
or ignition key cycled.
CAUTION
Be sure to deactivate the heavy mud/snow function when no longer needed.
Continued operation with the heavy mud/snow function active will result in vehicle
damage. If after a reasonable amount of time (no more than five minutes) the
vehicle is still not moving, deactivate the ATC and put on chains.
21. Cab Climate Control Panel — See the CAB CLIMATE CONTROL
section for more information.
22. Power Take-Off Control Switch (If Equipped) — Push the top in to turn
the PTO on. Push the bottom in to turn it off.
C0029596
23. Auxiliary Switch — As defined by the Body Builder.

24. Parking Brake Valve — Pull to apply. Push to release. Applies tractor
parking brakes and trailer brakes, if equipped.
25. Auxiliary Switch — As defined by the Body Builder.
26. Light Control Panel — See the LIGHT CONTROL PANEL section for
more information.
27. Combination Starter and Electrical Switch — Starts the engine and
activates the accessory relay. To start the engine, turn key clockwise. To
activate the accessories, turn the key counterclockwise. When the switch is
turned ON (in either direction), a warning buzzer will sound if air pressure is
below 448±34 kPa (65±5 psi); the buzzer will turn off as soon as sufficient air
pressure is restored. When the key is straight up and down, the switch is OFF.
28. Right-Hand Operation Switch — Allows the operator to switch to a
right-hand drive mode. To use:
Note: Speed is restricted to 2nd gear when operating the vehicle from the right-hand
side.
- Stop the vehicle.
- Put the transmission in NEUTRAL.
- Set the parking brake.
- Go to the right side of the vehicle.
- Flip the switch to the right.
29. Moto-Mirror Switch (If Equipped)
C0029597
30. Heated Mirror Switch (If Equipped) — Activates the outside heated
mirrors (for use in icy conditions).
C0029598
31. Resume/Set Switch — This is a V-MAC® switch; for more information,

refer to the applicable V-MAC® Operator’s Guide.
C0029150
32. Speed Control Switch — This is a V-MAC® switch; for more information,
refer to the applicable V-MAC® Operator’s Guide.
C0029211
33. Cigar Lighter — Press in the lighter; it will pop out when element is hot.
CAUTION
Maximum amperage for the in-dash cigar lighter is 10 amps. Do NOT use the cigar
lighter receptacle to power accessories rated higher than 10 amps.
or
Accessory Power Outlet — See instructions under Accessory Power Outlets
listed in the Instrument and Controls Section of this manual.
34. Air Pressure Gauge — Indicates the air pressure in the air brake
system(s). The normal operating air pressure is between 759 kPa (110 psi)
and 897 kPa (130 psi) in both air brake systems. If pressure drops below 75
psi (±5 psi) in either system, the warning buzzer and warning light will go
on. Determine the cause of failure before proceeding. Primary air pressure
is supplied to the rear brakes and is indicated by the green pointer on the
gauge. Secondary air pressure is supplied to the steering axle brakes and
indicated by the orange pointer.
35. Speedometer/Odometer — Indicates road speed in miles and/or
kilometers per hour and total distance vehicle has traveled.
CAB CLIMATE CONTROL
C0029599
1. Fan Control Switch 3. Temperature Control Lever

2. Mode Selection Lever
1. Fan Control Switch — Controls the amount of air delivered through the
vents. Down is OFF and up is HIGH speed. The middle positions are LOW
and MEDIUM speeds.
2. Mode Selection Lever — Allows the operator to choose the air direction.
The CAB position delivers air to the floor outlets, while the DEF position
directs air to the windshield for defogging and/or defrosting. Sliding the lever
in between positions provides a blend of the two.
3. Temperature Control Lever — Controls the temperature of air from COOL
(far left) to HOT (far right).
LIGHT CONTROL PANEL

This panel controls the parking lights, interior panel lights, headlights and
fog lights (if equipped).
C0029600
1. Light Control Knob/Pull for Fog 3. Hook-Up Lamps or Perimeter

Lighting (If Equipped)
2. Panel Dimmer Switch
With the light control knob in the left position, all lights are off. With the knob in
the middle position, the parking lights and interior panel lights will illuminate.
With the knob in the far right position, the headlights will turn on.
To turn on the fog lights (if equipped), put the knob in the far right position
and pull out the fog light button (see Figure above). The fog light symbol will
illuminate indicating the lights are on.
To adjust the intensity of the panel light, move the panel dimmer switch back
and forth.
To turn on the hook-up lamps or perimeter lighting (if equipped), push the
right switch up.
STEERING COLUMN
Combination Starter and Electrical Switch

Turn Signal Lever
Note: The turn signals are not self-cancelling and must be returned to the middle
position manually.
The turn signal lever is located on the steering column. It performs a number
of functions, including activating the high and low beams and the hazard
switch (see illustration on following page).
C0029601
1. Handle in Right Turn Position and 3. Pull for Warning Hazard Position
Cancel Position of Hazard Warning
2. Handle in Left Turn Position and 4. Push Button for Hi/Lo Beam
Cancel Position of Hazard Warning
MISCELLANEOUS CONTROLS
Dome Light
C0029602
Push the switch to the right to turn the dome light on. Push the switch to the
left to turn the dome light off.
Air Horn
C0029603
The air horn(s), if equipped, is activated by pulling down on the cord that is
located above the driver near the overhead console.
Fresh Air Vent
C0029604
An air vent, located in the driver side door, is provided to circulate outside air
to the cab interior. Move the vent lever forward or rearward to open the vent.
Move the lever to the center to close the vent.
Accessory Power Outlets

Additional 12-volt accessory power outlets are located next to the driver on the
"E" panel. These cigar light-type outlets supply 12 volts of fused (20A) power
when the ignition switch is turned to the ignition or accessory position.
C0029605
CAUTION
Maximum amperage for all power receptacles in cab is 20 amps. Do NOT exceed
maximum amperage as equipment damage may result.
PRE-TRIP INSPECTION AND DAILY
MAINTENANCE 73
PRE-TRIP
DANGER
Before working on or inspecting a vehicle, set the parking brakes, place the
transmission in neutral and block the wheels. Failure to do so can result in
unexpected vehicle movement and can cause serious personal injury or death.
Safety is the most important and obvious reason for doing a pre-trip inspection.
Federal and state laws require inspection performed by the driver. Federal
and state inspectors also inspect commercial vehicles. An unsafe vehicle can
be placed "out of service" until the driver or owner corrects the deficiency.
Owners and operators should familiarize themselves with sections 49 CFR
396.11 and 396.13 concerning Federal requirements for vehicle inspection.
Certain other laws may also apply.
Section 49 CFR 396.13 states that all motor carrier drivers must complete a
written report at the end of each work day for each vehicle operated, covering
most of what is covered in the pre-trip list. The report should list all defects
or deficiencies discovered by the driver. A pre-trip inspection prepares for
the end-of-work report.
Starting on the next page are suggested guidelines to be used in performing
truck, tractor and trailer pre-trip inspections. Depending on the application of
the vehicle being used, these guidelines should be modified to include other
necessary inspection points. For example, steps and grab handles should be
checked daily on refuse trucks because the operator is getting in and out
of the cab more frequently.
If any component or system does not pass this inspection, it must be corrected
before operating the vehicle. Whenever equipment requires adjustment,
replacement, repair or lubrication, refer to the Service Manuals or contact
an authorized Mack Truck dealer for the correct procedures, specifications
and intervals.
Take your time going through the pre-trip inspection. Remember that a careful
pre-trip inspection saves time by eliminating unscheduled stops for correcting
a faulty item.
The following information has been provided by the American Trucking
Association as developed by the D.O.T. Office of Motor Carriers (BMCS).
Pre-Trip Inspection Quick List

Inspect the vehicle in a circular manner.
Approaching the Vehicle

74 PRE-TRIP INSPECTION AND DAILY
MAINTENANCE
• Check under the vehicle for oil, fuel, coolant leaks or other signs of damage.
• Check body surfaces for signs of breaks or damage.
Preparation
• Open drain cocks on air tanks to let the tanks drain.
• Chock wheels on vehicle and, if hooked up, trailer.
• Close air tank drain cocks.
• Start the engine and let the air pressure build up to normal. Stop engine
check for air leaks.
• Switch on parking lights and hazard lights.
• Apply parking brakes. Listen for air leaks
• Raise cab so belts can be checked
Step 1: Left Side of the Cab

Left Front Wheel
• Check condition of wheel rim. Especially look for cracks, missing lockrings,
bent or broken studs, missing clamps or lug nuts.
• Check condition of tire: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stem not touching wheel, rim or
brake drum; valve cap in place.
• Check wheel bearing and hub: no obvious leaking on outside or inside
wheel. Verify correct oil level in hub.
Left Front Suspension

• Check condition of spring, spring hangers, shackles, U-bolts: no cracks,
breaks or shifting.
• Check shock absorber condition.
Left Front Brake

• Condition of brake drum. With brakes released, look for a noticeable gap
between lining and drum. (This check cannot be made if dust covers are
in place.)
• Condition of brake air hose.
• Check brake chamber mounting bolts and bracket.
MAINTENANCE 75
• Check slack adjuster and chamber pushrod travel for proper brake
adjustment.
Condition of Front Axle and Steering System, Left Side

• No loose, worn, bent, damaged or missing parts.
Engine Compartment, Left Side

• Check coolant hose condition.
• Check condition of fan drive belts.
• Check engine and surrounding areas for coolant, oil and fuel leaks.
• Check wiring harnesses for signs of damage.
Engine Compartment, Right Side

• Check condition of coolant and heater hoses.
• Check condition of fan drive belts.
• Check engine and surrounding areas for coolant, oil and fuel leaks.
• Check fuel separator sight glass and drain if necessary. Check for leaks.
• Check wiring harnesses for signs of damage.
• Check air filter with brackets and hoses for loose connections or damage.
Check filter gauge, if mounted on the filter.
Step 2: Front of Cab Area

Condition of Windshield
• Check for damage and clean if dirty.
• Check windshield wiper arms for proper spring tension.
• Check wiper blades for any damage, "dead" rubber and attachment to arm.
Lights and Reflectors

• Lower cab and inspect parking, clearance and identification lights on cab.
They should be clean, operating and of the proper color.
• Reflectors clean and proper color.
• Turn on headlights. High and low beams should be operating and lenses
clean. If equipped, check daytime running lights.
MAINTENANCE
• Left and right front turn signal lights clean, operating and proper color.
Grille
• Check that charge air cooler and radiator or bugscreens are clean and
undamaged.
Step 3: Right Side of Cab Area

Right Front Wheel
• Check condition of wheel rim. Especially look for cracks, missing lockrings,
bent or broken studs, missing clamps or lug nuts.
• Check condition of tire: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stem not touching wheel, rim or
brake drum; valve cap in place.
• Check wheel bearing and hub: no obvious leaking on outside or inside
wheel. Verify correct oil level in hub.
Right Front Suspension

• Check condition of spring, spring hangers, shackles, U-bolts: no cracks,
breaks or shifting.
• Shock absorber condition.
Right Front Brake

• Condition of brake drum. With brakes released, look for a noticeable gap
in place.)
• Condition of brake air hose: check for any chafing.
• Check brake chamber mounting bolts and bracket.
• Check slack adjuster and chamber pushrod travel. With brakes applied
or released, look for conspicuously different positions of the slack adjusters
for proper brake adjustment..
Condition of Front Axle and Steering System, Right Side

• No loose, worn, bent, damaged or missing parts.
Step 4: Right Saddle Tank Area

MAINTENANCE 77
Right Fuel Tank(s)

• Securely mounted Diesel and Diesel Exhaust Fluid are not damaged or
leaking.
• Fuel lines secure and not leaking. Check that shut-off valves are open.
• Tank(s) full of fuel. Cap on and secure.
Condition of Visible Components

• Rear of engine: not leaking.
• Transmission: not leaking. If equipped with oil cooler, check cooler, hoses
and fittings for leaks.
• Check drive shaft.
• Exhaust system: secure, not leaking, not touching wires, fuel or air tubing.
• Frame and cross members: no bends, cracks or breaks.
DPF/SCR check hoses and fittings for leaks.
• Air tubing and electrical wiring: secured against snagging and chafing.
Step 5: Right Rear Vehicle Area

Dual Wheels, One or Two Axles
• Check condition of wheels and rims. Especially look for cracks, missing
lockrings, bent or broken spacers, studs, missing clamps or lug nuts.
• Check condition of tires: properly inflated, no serious cuts, bulges, tread
wear or any signs of misalignment; valve stems not touching wheels, rims or
brake drums; valve caps in place and no objects stuck between the wheels.
• Check that both tires are of same type, for example, not mixed radial and
bias type and that their circumferences are matched.
• Check wheel bearing and hub: no obvious leaking on outside or inside wheel.
Suspension
• Check condition of springs (leaf), spring hangers, shackles and U-bolts.
• Axle alignment.
Brakes
• Condition of brake drums. With brakes released, look for a noticeable gap
in place.)
MAINTENANCE
• Condition of brake hoses: check for any chafing.

• Check brake chamber mounting bolts and brackets.
• Check slack adjusters and chamber push rod travel. With brakes applied
for proper adjustment.
• Check spring brakes.
Step 6: Rear of Vehicle Area

Frame Area
• Frame or cross members not bent, cracked or otherwise damaged or missing.
• Check that air tubing and electrical lines are properly secured to the frame
with no damage or chafing.

• Tail lights, brake lights and turn signal lights: operating, clean and proper
color.
Step 7: Coupling System Area

Fifth Wheel
• Securely mounted to the frame.
• No missing or damaged parts.
• Check that trunnion and plate are properly lubricated.
Sliding Fifth Wheel

• Mechanism not worn, bent, damaged or parts missing.
• Properly lubricated.
• All locking pins present and locked in place.
• If air operated: no air leaks.
Air Tubing and Electric Lines Visible From This Point

• Should be secure from dangling.
• Both air lines and electric line should be free from damage, oil and grease.
MAINTENANCE 79
Step 8: Left Saddle Tank and Left Rear Vehicle Wheels Area
Suspension
• Check condition of springs (leaf or air), spring hangers, shackles and U-bolts,
no cracks, breaks or shifting.
Brakes
in place.)
Condition of Visible Components

• Transmission: not leaking.
• Drive shaft: looks OK.
• Exhaust system: secure, not leaking, not touching wires, fuel or air tubing.
• Frame and cross members: no bends, cracks or breaks.
• Air tubing and electrical wiring: secured against snagging and chafing.
Left Fuel Tank(s)

• Securely mounted and not damaged or leaking.
MAINTENANCE
• Fuel lines secure and not leaking. Check that shut-off valves are open.
• Tank(s) full of fuel. Cap on and secure.
Battery Area
• Open the battery box. Battery box securely mounted to vehicle.
• Batteries secured against movement.
• Battery cases not broken or leaking. Battery cables free from damage.
• Tops of batteries and terminals clean and free from foreign material.
• If equipped, replace battery lid and make sure it is securely fastened.
In the Cab
• Check steps and grab handles for looseness or breakage. Also, clean
them if there is any substance that makes them slippery, which makes cab
entry/exit hazardous.
• Start the engine. If equipped, check that exhaust rain cap opens when
accelerating engine.
• Check gauges and tell-tale light function. See the Instruments and Controls
section.
• Check function of low air warning.
• Check clutch function. If equipped, check for clutch brake function.
• Check windshield wipers and washers and horns, including back-up alarm,
if equipped.
• Clean inside windshield, door windows and instruments. Clean mirrors.
• Check temperature control and defroster. If equipped, check mirror heater.
• Check condition of warning triangles, fire extinguisher and flares.
• Adjust the seat. Check mirror adjustment.
• Check safety belts for function and damage.
• Apply service brakes. After initial drop, pressure should hold steady, or
increase slightly, with engine at idle.
• Check steering wheel for excessive free play.
• Check for loose items in the cab. Secure them if necessary.
Hooking Up To Trailer
MAINTENANCE 81
Hook-Up Preparation
• Check kingpin and mounting plate on trailer, free from wear, bends or
damage.
• Chock trailer wheels.
Fifth Wheel or Trailer Hitch

• No visible space between fifth wheel and trailer.
• Locking jaws around the shank and not the head of kingpin.
• Release lever properly seated and safety latch/lock engaged.
• Check all connections to dolly or trailer hitch and safety chains are secured.
• Check function of trailer air supply valve and trailer brakes.
Sliding Fifth Wheel

• Check that fifth wheel is not so far forward that the tractor frame will strike
the landing gear during turns.
Note: Refer to the trailer manufacturer’s manual for specific information on the
trailer checks.
Step 9: Trailer Front Area

Air and Electrical Connections
• Glad hands properly mounted, free from damage and not leaking.
• Trailer cord receptacle properly mounted, free of damage; plug properly
seated and safety catch engaged to prevent accidental disconnect.
• Air and electrical lines properly secured against tangling, snagging and
chafing with sufficient slack for turns.
Step 10: Right Side of Trailer Area

Landing Gear or Dolly Area
• Fully raised; no missing or damaged parts.
• Crank handle present and secured.
• If power operated, no air/hydraulic leaks.
Spare Wheel(s)
MAINTENANCE
• Carrier or rack not damaged.

• Spare wheel securely mounted in rack.
• Tire and wheel condition adequate for a spare: proper size, properly inflated.

• Trailer side clearance lights: clean, operating and proper color.
Frame and Body

• Frame and crossmembers not bent, cracked, damaged or missing.
• Proper placarding.
• Body parts not damaged or missing.
Step 11: Right Rear Trailer Wheel

Suspension
• Condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
• Condition of torque rod arms.
• If equipped with sliding axles, check position and alignment. Look for
damaged, worn or missing parts, all locks present, fully in place and locked.
• Flexible air tubing not cracked, cut, crimped or otherwise damaged. Secured
against tangling, dragging and chafing.
Brakes
MAINTENANCE 83
in place.)
Step 12: Rear of Trailer Area

• Rear clearance, identification and tail lights clean, operating and proper color.
Cargo Securement
• Cargo properly blocked, braced, tied, chained, etc.
• Tailboard up and properly secured. End gates free from damage, properly
secured in stake pockets.
• Canvas or tarp (if required) properly latched down to prevent water damage,
tearing, billowing or blockage of either mirrors or tail lights.
• Rear doors securely closed, latched or locked; required security seals in
place.
• Underside guard in place: not cracked, bent or broken.
Step 13: Left Rear Trailer Wheels Area

• Check condition of wheels and rims. Especially look for cracks, lockrings
missing, bent or broken spacers, studs, missing clamps or lug nuts.
MAINTENANCE
Suspension
• Condition of springs (leaf or air), spring hangers, shackles and U-bolts.
• Axle alignment.
• Condition of torque rod arms.
• If equipped with sliding axles, check position and alignment. Look for
damaged, worn or missing parts, all locks present, fully in place and locked.
• Flexible air tubing not cracked, cut, crimped or otherwise damaged. It should
be secured against tangling, dragging and chafing.
Brakes
between lining and drum. (This check can not be made if dust covers are
in place.)
• Check slack adjusters and chamber push rod travel. With brakes applied or
released, look for conspicuously different positions of the slack adjusters.
Step 14: Left Side of Trailer Area

Landing Gear or Dolly Area
• Fully raised; no missing or damaged parts.
• Crank handle present and secured.
• If power operated, no air/hydraulic leaks.
Spare Wheel(s)
• Spare wheel securely mounted in rack with no damage to rack.
• Tire and wheel condition adequate for a spare: proper size, properly inflated.

• Trailer side clearance lights: clean, operating and proper color.
MAINTENANCE 85
Frame and Body

• Frame and crossmembers not bent, cracked, damaged or missing.
• Proper placarding.
• Body parts not damaged or missing.
Before Leaving the Parking Area

• Remove chocks from the wheels.
• Test trailer hook-up by slowly pulling while applying the trailer brakes with
the trailer brake hand control valve.
• Test the service brakes before leaving the parking area.
• Test parking brakes by stopping on a 20% grade and applying the parking
brakes. The parking brakes shall hold the combined vehicle and trailer without
moving.
86 OPERATION
New Vehicle Break-In

To ensure many years of reliable, trouble-free operation, the following break-in
procedures are recommended:
Note: Oil change, filter change and chassis lubrication are no longer required at
the 3,000-mile vehicle break-in interval.
Refer to the preventive maintenance schedules outlined in the Maintenance

and Lubrication Manual (21394653) for recommended lubrication change
intervals for the following items:
• Gear oils (transmission, rear axle carrier[s], front drive axle carrier, transfer
case, flywheel PTO)
• Engine oil
• Oil filters
• Fuel filters
• Coolant conditioner
Note: It is important that components be filled with lubricants meeting the

specifications as given in the Maintenance and Lubrication Manual (21394653)
Note: When checking oil levels, the vehicle must be parked on level ground, and
the units at normal operating temperature. Components must be filled to the correct
level. DO NOT OVERFILL.
Note: Oil and filter change intervals in this manual pertain to components built by
Mack Trucks, Inc. For information concerning oil and oil filter change intervals for
vendor components, refer to the specific vendor component service literature.
During the First 5000 Kilometers (3000 Miles)

• After the first 200 km (125 miles), retorque the wheel nuts using an accurately
calibrated torque wrench. Recheck this torque again after 800 km (500 miles).
• Check oil and coolant levels frequently.
• Check brake and clutch adjustments per recommended maintenance
schedule, and adjust as needed.
• Observe the instruments often, and shut down the engine at the first sign of
any abnormal readings.
• Report all leaks, loose fasteners, unusual noises, etc., to the service
representative at the nearest Mack dealership so they can be checked and
corrected.
OPERATION 87
• Check the spring clip torque (U-bolts). (On REYCO suspensions, also check
equalizer nut torque.)
• On chassis equipped with AIRTEK™ front axle air suspensions, retorque
the U-bolts.
• Check the U-bolt torque on the MACK air suspension at the end of the first
1600 km (1000 miles).
After the First 5000 Kilometers (3000 Miles) or Before 6400 Kilometers
(4000 Miles) or Before 3 to 4 Months
• Retorque the spring clip (U-bolts). (On REYCO suspensions, also retorque
the equalizer nut.)
Note: On chassis equipped with AIRTEK™ front axle air suspensions, check the
torque of the front axle U-bolts at 24 000 kilometers (15,000 miles).
At the First A Inspection Interval

• Check front and rear axle alignment and adjust if the alignment is out of
specifications.
• Check steering knuckle to axle beam clearance.
Although this quality-built vehicle has been inspected, lubricated and adjusted
at the MACK Trucks Assembly Plant, an occasional air, oil or coolant leak may
develop. Quick action to correct these minor items will prevent a major repair
later. Take the vehicle to the nearest MACK service center as soon as any
abnormal condition becomes evident.
Initial Valve Adjustment Intervals

Refer to the Maintenance and Lubrication Manual (21394653) for detailed
information concerning the Initial Valve Adjustment Interval also see page 223.
88 OPERATION
WINDSHIELD WASHER RESERVOIR

As shown in the drawing below, the windshield washer reservoir is located
on the driver-side back of the cab.
C0029606
OPERATION 89
CAB TILT OPERATION
DANGER
Before attempting to tilt the cab, be certain to take the following steps:
• Park on a level surface.
• Apply the parking brake.
• Place the gearshift lever in NEUTRAL position.
• Shut off the engine.
• Secure all loose items within the cab.
• Close the cab doors.
The cab is mounted on the chassis frame by two front hinges and two rear
cab locks. This arrangement allows the cab to tilt forward to a maximum of 60
degrees, exposing the engine compartment for easy accessibility.
The cab tilt system uses one hydraulic cylinder. It incorporates internal safety
valves which lock up automatically if the cab moves too rapidly in either
direction.
The hydraulic fluid pressure imbalance forces the check valves to seat,
holding the cab in a hydraulically locked position. If this situation occurs,
operate the pump in the opposite direction to open the check valves. The
system will then be returned to normal operation.
90 OPERATION
Tilting the Cab

Use the following instructions to tilt the cab:
Note: Before raising the cab, the engine must be shut off and all loose items in the
cab must be secured.
1. Take the cab tilt pump handle from its stored position.
Note: The cab tilt pump handle is stored inside the cab, on the right side cab back
wall, behind the folding seat.
2. Insert the handle into the pump and move the pump control lever (see
arrow) to the RAISE position (refer to the illustration).
C0029607
Pump Control Lever (Arrow)

OPERATION 91
3. To raise to the service position, pump the cab up to the SERVICE HEIGHT
position.
C0029616
1. Safety Prop
Note: In the service position, the cab must be secured with the safety prop (see
illustration).
4. To secure the cab in the service position, loosen the thumbscrew and swing
the safety prop down onto the safety prop stud (see arrow). The slot in the
safety prop should settle securely around the stud (refer to the illustration
above).
WARNING
Be certain that there are no people, tools or unsecured vehicle parts in the path
of the descending cab before shifting the pump control lever.
5. It may be necessary to manipulate the pump control lever, while the cab is
descending, so the safety prop settles on the stud.
92 OPERATION
C0029617
1. Cab Full Tilt Position
6. To raise the cab to the full tilt position, pump the cab up past the balance
point. Note that the cab will descend by itself, although the rate of descent
may be controlled by manipulating the pump control lever from the RAISE to
LOWER position.
Lowering the Cab

Note: Before lowering the cab, the cab safety prop must be in the stored position and
the transmission must be in NEUTRAL.
1. Move the pump control lever to the LOWER position.

2. Pump until the cab is past the balance point and allow the cab to descend
and latch.
3. Leave the pump control lever in the LOWER position while the vehicle is
in operation.
OPERATION 93
Bleeding the Cab Tilt System

Note: In order to bleed the system, the cab must be in the lowered position.
Note: To perform a system bleed, the following steps must be performed in the
designated order:
1. Connect all hydraulic lines.

2. Tighten all connections (except two) at the tilt cylinder.
3. Tighten one connection at each latch cylinder.
4. Fill the pump reservoir to the top with MACK specified oil.
CAUTION
Do not refill the reservoir with the cab in the RAISE position.
5. Close and tighten the fill plug.

6. Shift the pump control lever to the LOWER position and pump until the
LOWER lines are bled; also tighten the corresponding connections.
7. Shift the pump control lever to the RAISE position and pump until the
RAISE lines are bled; also tighten the corresponding connections.
8. Bleed the latch cylinders and tighten the connections.
9. Bleed the push port of the tilt cylinder and tighten the connections.
10. After the entire system has been bled, shift the pump control lever to the
LOWER position; then check and refill the reservoir, if necessary.
Note: The recommended type of fluid for the cab tilt system is CF-A (MIL-H-5606E);
the approximate capacity is 1.4 liters (3 pints).
WARNING
The pump control lever must be in the LOWER position before operating
the vehicle.
94 OPERATION
DOORS
Opening the Cab Door

The inside door handles are flush-mounted, with paddle-type design. To open
the door, grasp the handle and pull out while exerting some force on the door.
C0029618
Note: If the door is locked, slide the button to unlock the door before pulling the
inside paddle handle.
Locking the Cab Door

To lock with the door open, press the door handle inward and shut the door.
To lock with the door closed (from the inside), slide the lock button down;
to unlock, slide the lock button up.
Right-Side (Folding) Door
CAUTION
Be sure not to disturb the rear view mirror when folding and unfolding the
right-side door.
Folding the Door

OPERATION 95
1. Open the right-side door. Note that the right-side door opens the same way
as the left side, using a paddle-type handle.
C0029619
2. With the door open at least halfway, lift up on the door bottom and fold the
door in half (refer to the illustration).
3. Push the bottom half of the door tight against the top half to secure the
folded door.
4. In this position, the door latch will act as a holding device to secure the
bottom half of the door. There is also a rubber ball-and-socket arrangement
that will interlock (with about 6 or 7 pounds of pressure) at the door top and
bottom.
5. Push against the folded door to securely latch it to the catch on the rear of
the cab.
Unfolding the Door

Before returning the right-side door to its whole-door configuration, it must be
securely latched to the back of the cab.
96 OPERATION
C0029620
1. Pull the paddle handle door latch (see arrow) and use both hands to
support the door while unlatching the ball and socket (which is holding up the
lower half of the door). Refer to the illustration.
2. While supporting the folded door section with your right hand, pull the
lanyard cord (see arrow) to unlatch the door assembly from the cab. Refer
to the illustration.
OPERATION 97
C0029621
3. Pull the door about six inches away from your body, and carefully lower the
folded section to the whole-door position.
Bi-Fold Doors
The LEU model can be equipped with optional bi-fold doors on both sides
of the chassis. Procedures for unfolding and folding the door are the same
on both sides of the vehicle.
Folding the Door

1. Disconnect the door limiting strap by pulling the loop of the strap over the
end of the post on the door.
98 OPERATION
C0029622
2. Rotate the bi-fold latch handle upward to disengage the slot. Pull the
handle rearward to unlatch the bi-fold door panels.
C0029623
3. Fold the two door panels until they latch together. In this position, the cab
door latch acts as a holding device to secure the bi-fold panels together.
4. Open the door fully until engaging the latch at the front of the cab that holds
the door in the fully opened position.
OPERATION 99
C0029624
100 OPERATION
Unfolding the Door

1. Push the door latch lever located on the front of the cab to disengage
the door panels from the cab.
C0029625
2. Pull the outside door handle to separate the two door panels.
C0029626
3. Unfold the door panels.

4. Slide the bi-fold door latch handle forward to lock the two panels together.
Rotate the lever downward to lock the handle in place.
C0029627
OPERATION 101
5. Reinstall the door limiting strap.

102 OPERATION
SEAT BELTS
DANGER
Seat belts should always be secured BEFORE the vehicle is set in motion.
Failure to use seat belts can result in SEVERE bodily injury or death. Unbelted
riders could be thrown into the windshield or other parts of the cab, or thrown
out of the cab entirely.
Seat Belt Operation

MACK vehicles manufactured on or after September 1, 1990 must have
locking retractable seat belts.
This type of belt is designed to lock (prevent belt travel out of the retractor)
only during sudden stops or impacts. This feature allows the operator to move
freely under normal conditions. Seat belts cannot be locked by jerking on the
belt, except during sudden stops or harsh bumps.
For the left-side seat position, this type of seat uses a combination lap and
shoulder belt. For the right-side seat position, there is an automatic locking
retractor for the lap belt only, with no shoulder belt. The belt will relock at
about one-inch intervals as it rewinds into the retractor. Be sure to pull enough
webbing out of the retractor before stopping to insert the end of the belt into
the seat belt buckle. Once it is buckled, the retractor will pull up the excess
webbing and relock.
Fastening Seat Belt

1. Pull clip so the belt crosses your shoulder and lap and insert it into the
buckle until an audible snap is heard.
DANGER
Use the shoulder belt only on the shoulder that is closest to the vehicle door.
Never wear the shoulder portion of the belt under your arm or behind your back.
Improper use will increase your chances of injury during a collision.
OPERATION 103
DANGER
To prevent possible injury the belt must be positioned low over the pelvis, below
the abdomen. If the belt is buckled too high, it will apply force to the abdomen, not
the pelvic region, and could cause serious internal injuries during a sudden stop.
DANGER
Do NOT wear seat belt loosely. Do NOT use one belt for more than one person.
2. Make sure the clip is securely fastened into the buckle.
C0029326
3. To tighten the lap portion of the combination belt, pull upward on the
shoulder portion until the lap portion fits snugly. The belt should rest as low on
your hips as possible.
104 OPERATION
Unfastening Seat Belt

Push down on the button to release the belt.
Seat Belt Maintenance

• Keep belt clean and dry.
• Clean with mild soap solution and lukewarm water.
DANGER
Do NOT bleach or dye belt, as this may cause severe loss of strength. Do NOT
install belt in a truck with a weakened floor until the floor has been replaced
or reinforced.
• Periodically inspect the following areas and replace any inadequate parts:
Buckle and Latchplate — The buckle and latchplate should mate easily
with a solid click and release easily and quickly with moderate pressure on
the release button. All metal seat belt components should be free of signs of
damage, corrosion or rust.
Webbing — The webbing should show no signs of wear, fraying or holes, and
it should be reasonably free of dirt which could find its way into the retracting
mechanism.
Retractors — The retractors should function smoothly and maintain
an appropriate amount of tension. Loose webbing is an indicator that
maintenance is needed; it’s likely that a too-loose belt will fail to tighten
properly when necessary.
Seat Belt Mounting Components — The tethering should be free of wear
and debris; the webbing should show no signs of wear, fraying or holes; and
the metal components should be free of signs of damage, corrosion or rust.
DANGER
Seat belt assemblies must be replaced after an accident if they have been
subjected to loading by occupants (even if no damage is obvious), or if they have
been damaged by an accident (bent retractor, torn webbing, etc.). If there is any
question regarding belt or retractor condition, replace the appropriate part.
OPERATION 105
RIGHT-SIDE RESTRAINT
C0029628
DANGER
When the seat is in the standing (drive) position and the door is open, pull out
the orange-colored retractable webbing and engage the end into the buckle in
the instrument panel. This will serve as a door-opening restraint.
106 OPERATION
SEAT ADJUSTMENT
Right-Side Folding Seat

Note: This vehicle was designed as a left-hand drive cab with right-hand operating
position. It is possible to operate this vehicle from either side, but the person on the
right must be seated to ride and must stand to drive.
C0029629
Stand facing the seat. Reach behind the seat and pull on the latch. Fold the
seat to a vertical position to stand, or set it level for the seated position.
DANGER
Seat belts must be worn at all times while operating this vehicle.
OPERATION 107
Air Seat
C0029630
1. Lumbar Adjustment Knob 4. Weight and Height Adjustment

Button
2. Seat Back Adjustment Lever 5. Seat Cushion Tilt Adjustment Knob
3. Optional Air Lumbar Adjustment 6. Fore/Aft Adjustment Lever
Button (Upper and Lower)
DANGER
Do not make seat adjustments while the vehicle is in motion, as this could cause a
loss of vehicle control, resulting in an accident which results in severe personal
injury or death.
Lumbar Adjustment
Rotate the knob [1] forward to increase or rearward to decrease the support in
the lumbar area.
Seat Back Adjustment

108 OPERATION
1. Lean forward slightly to remove your weight from the seat back.
2. Pull the seat back angle adjustment lever [2] rearward to release.
3. Adjust the seat back to the desired position within range of adjustment, then
release the handle to lock the seat back into place.
Air Lumbar Adjustment Button (Optional)

1. To increase lumbar support, press button [3] forward.
2. To decrease lumbar support, press button [3] rearward.
Weight and Height Adjustment Button

1. To raise the seat, push the air valve button [4] upwards.
2. To lower the seat, push the air valve button [4] downwards.
When adjusted properly and under normal driving conditions, the seat should
not top or bottom against the end limits of the vertical travel. Adjusted height
position should aid the driver’s visibility and vehicle control.
Seat Cushion Tilt Adjustment Knob

Rotate the seat tilt knob [5] to decrease or increase seat tilt.
Fore/Aft Adjustment Lever

1. Hold the fore and aft adjustment lever [6] to the left.
2. Slide the seat to the desired position.
3. Move the lever to the right to lock the seat position. (Isolation of the seat is
provided when the lever is in the center [straight] position.)
OPERATION 109
MIRROR SYSTEMS
The mirror system for LEU model chassis are designed so that:
• Appropriate mirror views are available from both operating positions.
Moto Mirror System

The mirrors of the Moto Mirror System can be adjusted at any time (from
inside the cab) using the adjustment switches located on the center instrument
panel (Panel E).
Positioning the Mirrors
Note: The operator must readjust the mirrors when changing between left- and
right-operating positions.
There are 2 different styles of mirror mounting arrangements available.

On the first arrangement, the left hand mirror is mounted on the door and the
right hand mirror is mounted on the door. Mirrors are positioned in such a way
so as to be viewed through the door windows. The mirrors must be readjusted
when changing positions as shown in the following illustrations:
C0029631
1. Forward 3. LH Driving Position

2. Wipers Must Park at the "Inboard"
Position
110 OPERATION
C0029632
1. Forward 3. RH Driving Position

Position
C0029633
1. Forward 3. LH Driving Position

Position
OPERATION 111
C0029634
1. Forward 3. RH Driving Position

Position
112 OPERATION
MACK ENGINE INFORMATION

For engine starting procedures, refer to “STARTING THE VEHICLE”, page
134.
Precautions and Warnings
CAUTION
If a winterfront is needed, use only a winterfront that was designed for this specific
chassis. Winterfronts are not recommended, but may be used during very cold
weather with sustained temperatures below -25°C (-13°F).
CAUTION
Be sure to avoid high intake/exhaust temperatures when using winterfronts under
normal operating conditions (above freezing). The restriction of airflow can cause
higher exhaust temperatures, power loss, excessive fan usage and reduced fuel
economy.
CAUTION
If a winterfront is used, a MACK-approved exhaust pyrometer must be installed and
closely monitored while the engine is in operation. Do NOT exceed the maximum
temperature indicated by the red line on the gauge. To reduce exhaust temperature,
downshift or reduce engine power and open the winterfront.
CAUTION
Do not permit a heavy load to drive the engine above the governed speed. Operate
in a gear low enough to allow the engine to accelerate to (or maintain) governed
speed when applying the throttle.
OPERATION 113
WARNING
Misuse or modification of a turbocharger can result in serious injury and
property damage. In addition, extreme care must be taken to avoid foreign
material induction, excessive exhaust temperatures and lack of lubrication.
CAUTION
The maximum allowable engine speed is listed on the warning label on the sun
visor. DO NOT exceed 2,300 rpm.
Engine Model Designations

The MACK engine model designation system uses letters and numbers to
provide a complete unit description.
MP Engine ID Letters and Number
C0029329
MP7 Used as an Example
1. Mack Power 3. Curve Family:

Econodyne = E
Maxicruise = C
Maxidyne = M
2. Peak Horsepower 4. Rounded Cubic Inch Displacement
114 OPERATION
CRUISE CONTROL OPERATION

Note: Effective August 2008, a change was made to the vehicle software which
requires the vehicle operator to press and release the brake pedal after the engine
has been started. If the brake pedal is not depressed after starting the engine, cruise
control will not function.
Speed Control Switches

Resume/Set Switch — Allows the driver to set and resume cruise control.
Note: In most cases, the Speed Control switch must be in the ON position in order
to use the Resume/Set switch. However, when the Initial Set Using Resume Switch
feature is enabled, cruise control can be activated using the Resume/Set switch.
The Resume/Set switch also functions as the Accel/Decel switch. Usually the
Resume position (press the top) corresponds to an increase in engine speed
(Accel) and the Set position (press the bottom) corresponds to a decrease in
engine speed (Decel).
Note: Under specific circumstances this switch can also be used to activate cruise
control. For details concerning the Initial Set Using Resume Switch feature, refer to
the V-MAC Support Software User’s Guide.
Speed Control Switch — Activates the cruise control system.
At the desired speed, press and release the Resume/Set switch. This speed
is now programmed and will be automatically maintained.
Note: To increase the engine speed, press and hold the Accel switch until the desired
speed is attained, or press the accelerator pedal until the desired speed is attained
and then press and release the Set switch.
OPERATION 115
Disengaging Cruise Control

To turn off the cruise control system, move the Speed Control switch to the
OFF position.
Note: If the Speed Control switch is moved to the OFF position, the process of setting
cruise control must be repeated in order to re-activate cruise control (unless the Initial
Set Using Resume Switch feature is enabled).
To temporarily disengage cruise control, disengage the clutch or apply the

service brakes.
Note: If cruise control is temporarily disengaged using the clutch or service brakes,
press the Resume switch to resume the previously programmed speed.
116 OPERATION
MACK POWERLEASH™ ENGINE BRAKE (IF

EQUIPPED)
Note: If your vehicle is equipped with a Jacob’s engine brake, please refer to the
Jacobs Engine Brake Manual supplied with the vehicle for complete operating
instructions.
Engines may be equipped to be PowerLeash™ upgradeable. These engines

will be equipped with PowerLeash™ camshaft. These engines are identified
on the engine information sticker.
If your vehicle is equipped with the MACK PowerLeash™ Engine Brake, it is
important that you take the time to become familiar with your engine brake
before putting it into operation.
WARNING
Operation of any vehicle on wet or slippery roads requires extreme caution.
Because the engine brake converts the engine to a retarding device, it should
NOT be used on wet or slippery roads if the vehicle has a single driving axle
or if it has tandem driving axles that are lightly loaded. Use of an engine
brake under these conditions can cause the vehicle to skid or a combination
vehicle to jackknife.
OPERATION 117
Engine Brake Switch

The Engine Brake switch is located on the dashboard. The Engine Brake
switch is a three-position switch located on the instrument panel.
C0029330
To operate the vehicle without the engine brake active, leave the
dash-mounted switch in the OFF position.
CAUTION
The V-MAC® system prevents engine brake activation if the oil temperature is
below 55°C (131°F). The driver should be alert to the fact that the engine brake
will not function until sufficient warm-up time has elapsed, regardless of the dash
switch setting.
How the Engine Brake is Activated

When the engine brake is "enabled" (switch in either LOW or HIGH position),
your engine V-MAC® electronic control system commands engine brake
power (engine brake "active") only when the following conditions are true:
• The foot-operated engine accelerator pedal is not depressed.
• The clutch pedal is not depressed (manual shift transmissions only).
• The engine speed is at least 900 rpm.
• Vehicle must be in gear.
• Vehicle speed should be greater than 8 km/h.
If the engine brake is active, the engine brake will automatically be deactivated
by depressing either the accelerator or the clutch, or if the engine speed drops
below 900 rpm. As soon as all of the engine brake "active" conditions are
again true (taking your foot off the accelerator, for example), the engine brake
118 OPERATION
will again be activated. In order to disable the engine brake, simply return the
dash-mounted control switch to the OFF position.
DANGER
The engine brake should never be considered a substitute for the vehicle service
brakes. The service brakes should always be maintained in good working order,
and should always be viewed as the primary vehicle slowing system. Service
brakes are always used to bring the vehicle to a complete stop.
Cruise Control with the MACK PowerLeash™

Engine Brake
When the MACK PowerLeash™ Engine Brake is enabled at the same time
your V-MAC® cruise control is in use, the engine brake automatically activates
when necessary to slow the vehicle to the cruise set point speed. You can
select one of two possible options:
• The engine brake is activated 3 kph (2 mph) above the cruise set point.
• The engine brake is activated as soon as cruise control commands fueling to
zero (vehicle has just reached cruise set point and fuel has been turned off).
The first option is the more popular choice for highway use and is the default
mode. Consult your V-MAC® IV Operator’s Manual for more information
about this option. Your local MACK dealer can change the current selection.
The engine brake’s ability to control maximum vehicle speed is limited
to the selected retarding power of the engine brake. If the engine brake
dash-mounted control switch is set to the LOW position, only half of the
available braking power is used. If the dash-mounted control switch is set to
the HIGH position, the cruise control invokes full engine brake power.
Note: Deactivating the cruise control function does not disable the engine brake.
The MACK PowerLeash™ Engine Brake may be activated or deactivated by

other vehicle systems such as ABS and Headway control systems. Refer to
the literature concerning these systems for additional information.
OPERATION 119
ON THE ROAD WITH THE MACK POWERLEASH™

ENGINE BRAKE
If you are not familiar with the use and operation of a heavy-duty diesel
engine brake, it is essential that you read the following section carefully. It is
very important that you take the time to gain experience with your MACK
PowerLeash™ Engine Brake in good driving conditions, before using it in
difficult or hazardous driving conditions, such as steep descents or slippery
roads. Of course, there is no substitute for driver training by a qualified
specialist.
The following information is intended as a guideline to safe and appropriate
use of the MACK PowerLeash™ Engine Brake. It is difficult to describe
every possible driving condition. Certain circumstances may require a more
conservative approach than will be described. When encountering any new
driving route or situation, err on the side of caution.
Over Flat Terrain

The LOW power position is likely adequate to control vehicle speed in
situations where the roadway is relatively flat or has modestly graded rolling
hills, and if total vehicle weight is light.
C0029331
1. High 3. Off
2. Low
120 OPERATION
As grades and vehicle weight increase, it will be necessary to use the HIGH
position.
C0029332
1. High 3. Off
2. Low
Descending a Grade
DANGER
The MACK PowerLeash™ Engine Brake assists you in establishing faster
downhill descent speeds than in a similarly configured and loaded vehicle without
an engine brake; nevertheless, even with an engine brake, there are limits to the
maximum vehicle speed at which you can travel on downhill grades and still
keep your vehicle safely under control. Always approach these situations with
caution, and gain the experience necessary for each grade and driving condition
to determine the appropriate downhill descent speed.
For a certain vehicle and load condition, a "control speed" may be established
for a given descent. The control speed is the vehicle speed at which the
retarding forces of air drag, rolling resistance and engine brake power are
equally balanced by the natural force of gravity that causes the vehicle to
accelerate down the hill, resulting in a steady, controlled vehicle speed. The
additional vehicle slowing power offered by the MACK PowerLeash™ Engine
Brake allows the driver to descend the hill in a higher gear than normal (at a
faster control speed), without overspeeding the engine.
For example, consider that you are descending a grade with a specific vehicle
and an assumed total vehicle weight. You will find that without an engine
brake, you must descend this grade in third gear to maintain a steady 16 kph
(10 mph) at 2,000 engine rpm, without the need to apply the service brakes.
OPERATION 121
C0029333
1. Descent Speed without MACK Engine Brake
Switch the MACK PowerLeash™ Engine Brake to the HIGH position, and now
it is possible to descend the same grade in sixth gear to maintain a steady 56
kph (35 mph) at 2,000 engine rpm.
CAUTION
The maximum allowable engine speed is listed on the warning label on the sun
visor. Do NOT exceed 2,300 rpm.
C0029334
1. Descent Speed without MACK Engine Brake

122 OPERATION
In any gear selection higher than sixth gear (in this example), it would be
necessary to occasionally apply the service brakes to maintain a safe vehicle
speed and to avoid overspeeding the engine.
DANGER
As with any vehicle, regular and excessive application of the service brakes
during a downhill descent can lead to a brake lining overheat condition, resulting
in a very dangerous loss of service brake retarding capability.
Note: The previous figures apply only to this hypothetical example. Specific vehicle
control speeds and engine speeds for a given descent are dependent upon the actual
vehicle and engine configurations, the gross weight of the vehicle, and the percent
grade of the road.
On Slippery Road Surfaces

As with many aspects of operating a heavy-duty vehicle, special care should
be taken when using the MACK PowerLeash™ Engine Brake on slippery road
surfaces. The potential for unpredictable loss of vehicle traction is a serious
concern; in some situations the engine should not be used at all.
As always, approach untested driving conditions with caution. Avoid use of the
MACK PowerLeash™ Engine Brake in these situations until you have gained
some experience under normal driving conditions.
As a rule, make sure that the vehicle is demonstrating good tractability with the
engine brake off before checking for tractability with the engine brake enabled.
Then, provided traffic conditions are safe for "testing" tractability, switch the
MACK PowerLeash™ Engine Brake to the LOW position. If the vehicle shows
any signs of loss of control (ABS activation or vehicle swerving, for example),
immediately switch the engine brake back to the OFF position.
OPERATION 123
C0029335
1. High 3. Off
2. Low
Only if the vehicle demonstrates good control in the LOW position (again, only
in safe driving conditions) should you test in the HIGH position, if desired.
Return to the LOW position and proceed with caution if there is any sign of
loss vehicle control.
Note: Always monitor vehicle tractability in slippery road conditions, and make
adjustments to engine brake switch position and vehicle speed as necessary. Always
test the LOW power position setting before moving to the HIGH position.
Your MACK PowerLeash™ Engine Brake and ABS control systems are
designed to work together for optimized vehicle control. The engine brake
function may be modified or interrupted briefly in the event of pending wheel
lock.
124 OPERATION
BRAKE OPERATION
Air Brake System

This chassis features a dual braking system which has two complete air
circuits: a primary circuit for rear brakes and a secondary circuit for front
brakes. Each circuit receives air from separate reservoirs. Although there are
two air circuits, they operate as one brake system through the dual-circuit
treadle valve. This provides the driver with easy, graduated control when
applying and releasing the brakes.
The air pressure in the two circuits is monitored by gauges on the instrument
panel. When air pressure drops below 517 ± 34 kPa (75 ± 5 psi) in either
system at any time other than vehicle startup, pull to the side of the road and
determine the problem. If air pressure continues to drop below 40 ± 5 psi in
BOTH systems, spring brakes will automatically apply. The Low Air Pressure
Warning indicator and buzzer will be activated if low air pressure occurs
in either circuit.
In tractor applications, the Trailer Supply Valve (red octagonal knob) will
immediately pop out in the event of a trailer breakaway or sudden trailer air
line failure, which will apply the trailer spring brakes. In the event of a slow
leak in the trailer air system, the trailer supply valve will pop out when system
Pressure reaches 70 psi. This protects the tractor air system from further
pressure loss.
If the Trailer Supply Valve is held in, in an attempt to override application of
the trailer spring brakes, the Park Brake Valve (yellow diamond knob) will
automatically pop out and apply the parking brakes when system pressure
drops to approximately 20–30 psi.
The air brake system consists of three main elements:
• The compressor, governor and reservoirs supply and store the air pressure.
• The brake application valve controls the brake application pressures.
• The brake chambers control the brake mechanism.
Air Brake Operation
CAUTION
Avoid sudden stops. Constant, sudden stops may negatively affect the performance
of braking and driving parts.
OPERATION 125
When slowing for a stop, leave the clutch engaged for as long as possible to
use the braking effect of the engine. When forward speed has dropped to a
little above idling speed, push clutch pedal in and brake to a complete stop.
Automatic Slack Adjusters

Automatic slack adjusters are designed to automatically maintain proper brake
chamber pushrod travel and compensate for brake lining wear during normal
use. Manual adjustment of an automatic slack adjuster should never be
performed except when performing brake or wheel service (such as backing
off the brake shoes for wheel removal, brake shoe relining/replacement, brake
drum reconditioning, etc.).
When pushrod travel exceeds specifications (as given in the "BRAKE
ADJUSTMENT" section of the Maintenance and Lubrication Manual,
21394653) on a vehicle equipped with automatic slack adjusters, a mechanical
problem with the slack adjuster, brake components or improper installation of
the slack adjuster is indicated. If brakes are found to be out of adjustment,
the vehicle must be taken to the nearest repair facility to have the problem
investigated and corrected.
DANGER
Automatic slack adjusters should not be manually adjusted in an effort to correct
excessive pushrod stroke, because this condition indicates that a problem exists
with the automatic adjuster, with the installation of the adjuster, or with related
foundation brake components, which manual adjustment will not fix. Manual
adjustment of automatic slack adjusters is a dangerous practice that could have
serious consequences, because it gives the operator a false sense of security
about the effectiveness of the brakes, which are likely to go out of adjustment
again soon.
Parking Brake System

Spring-type parking brakes are standard on all single and tandem rear axles.
The spring brake system consists of an air cylinder with heavy springs, which
is integrated with the spring brake air chamber. When there is no pressure in
the air chamber, the springs expand (causing a brake application). When air
pressure is applied to the air chamber, the springs are compressed (releasing
the brakes).
126 OPERATION
Parking Brake Operation

The parking brakes can be applied and released from the cab, using the
hand-operated push/pull control valve with the yellow diamond knob.
In the event of a significant air pressure loss in both the air brake systems,
the spring brake air chambers will be automatically exhausted (applying the
brakes). The parking brakes will remain applied until enough pressure is
available to recompress the springs.
Parking
WARNING
• ALWAYS apply the parking brakes when parking and make sure the parking
brakes are holding the vehicle from moving before leaving the driver’s seat.
• When parking on a grade, use wheel chocks under the rear wheels or turn
the front wheels to the curb. Do not leave diesel engine vehicles in gear; if the
vehicle should move, the engine may start by heat of compression.
• Check brake adjustment frequently to be sure that the brakes will lock and
hold the vehicle when parked.
• Do not use the parking brake to slow or stop the vehicle when in motion,
except in an emergency.
• Do not use hand control valve for parking.
OPERATION 127
Anti-Lock Brake System (ABS)

ABS Operation
When operating an ABS-equipped vehicle, the following guidelines should
be used.
• Apply the brakes as normal. If the anti-lock brake system begins to function,
maintain brake pressure. Do NOT release the brakes.
• Avoid rapidly pumping the brakes. The anti-lock brake system automatically
applies and releases the brakes up to five times per second.
MACK Road Stability Advantage (If Equipped)
The MACK Road Stability Advantage (RSA) is based on the Bendix® ABS-6
Advanced with ESP® (Electronic Stability Program) System. The RSA system
aids the operator in maintaining control of the vehicle in the event of a
jackknife or rollover situation by applying select brakes and reducing engine
power as required by the specific situation. The RSA system, which is integral
with the anti-lock brake system, uses the standard ABS components (such
as wheel speed sensors and modulator valves) along with a Steering Angle
Sensor (SAS-60™) and a Yaw Rate/Lateral Acceleration Sensor (YAS-60™)
package to provide information concerning vehicle movement to the Advanced
EC-60™ Electronic Control Unit.
In most cases, vehicle repairs will not affect function of the MACK RSA
system. However, the following repairs require recalibration of the SAS-60™
sensor after the repair has been made:
• Removal and reinstallation or replacement of the SAS-60™ sensor
CAUTION
Installation of an aftermarket steering wheel may damage the SAS-60™ sensor.
It is therefore recommended that the OEM steering wheel NOT be replaced with
an aftermarket wheel.
• Any repairs to the steering system or front suspension such as:

— Replacement of front springs
— Replacement of king pins or bushings
— Replacement of the steering gear
— Replacement of the drag link, cross steering tube or ball sockets
— Replacement of the front spring hangers
— Replacement of the steering column
128 OPERATION
• Front end alignment

• Disconnecting the steering column from the steering gear, or the steering
linkage from the steering gear
WARNING
Failure to recalibrate the steering angle sensor after performing any of the
repairs mentioned above, may affect proper function of the RSA system,
resulting in a loss of vehicle control due to system intervention at inappropriate
times.
Vehicle Modifications
Alterations to the vehicle, such as changes to the wheel base (either
lengthening or shortening), the addition of an auxiliary lift axle or removal
of a factory-installed auxiliary lift axle, or major body changes, such as
conversion of a tractor to a truck or an axle, suspension or steering system
component modification, are NOT allowed, as these changes will adversely
affect performance of the road stability system. Should such changes be
unavoidable, the system must be disabled by having a qualified technician
replace the Advanced EC-60™ ECU with a Premium EC-60™ ECU.
WARNING
Failure to disable the RSA system on a vehicle that has been modified
will result in serious vehicle braking and performance issues, including
unnecessary system interventions. These interventions could lead to a loss of
vehicle control.
In addition to disabling the system, any cab labels, such as warning and
caution labels relating to the Bendix® ABS-6 Advanced with ESP® system
located on the sun visor must be removed, and notations must be made to the
operators manuals so that the vehicle operator has a clear understanding as
to which ABS options are installed on the vehicle.
Location of the yaw rate/lateral acceleration sensor must not be altered.

When servicing is required, the sensors must be replaced with identical
components using the original equipment mounting brackets and tightening
torque specifications (20 N.m [15 lb-ft]).
The following additional changes MUST NOT be made to an "as-built" vehicle:
• Changes to maximum steering angle (to the left or right)
OPERATION 129
• Changes to steer axle and/or drive axle track width

• Changing the front and/or rear brake drums to drums having a different
flange thickness
Tire Size Calibration

The ECU requires a precise rolling circumference ratio between the front steer
axle and the rear drive axles for optimum performance of the system. For
this reason, the system continuously calculates the precise ratio and stores
the information in the ECU memory.
CAUTION
Effectiveness of the RSA system relies on the accuracy of the reported vehicle
speed. If major changes to tire sizes are made, such that changes to the vehicle
speedometer/odometer settings are required, the Advanced EC-60™ ECU must be
reprogrammed with the new values by a qualified technician.
Precautions When Installing Electrical Equipment

Connecting electrically powered or electrically controlled equipment to the
vehicle may cause interference with other vehicle components (e.g., the ABS
system). The amount of interference will depend on the operating frequency
of any new signals and the degree to which transient signals are coupled
into the vehicle system.
Note: Whenever new electrical equipment is installed, it is the obligation of the

installer to ensure that the new equipment does not interfere with the proper operation
of all other electrical systems on the vehicle.
If new electrical equipment is installed, a vehicle checkout procedure should

be performed.
1. Perform the checkout procedure under the following conditions:
• Engine running
• Brake system air pressure in operating range
• Vehicle stationary
• Brake pedal fully depressed
2. Operate the new equipment under all starting, running and shutdown
conditions.
130 OPERATION
3. Listen for signs of air exhausting from ABS modulator valves (which is an
indication of an interference condition).
4. Correct all interference conditions before operating the vehicle.
Automatic Traction Control (ATC) (If Equipped)

Automatic Traction Control (ATC) provides improved traction on slippery
surfaces by reducing wheel spin. The system operates automatically as
follows:
• If a drive wheel starts to spin, ATC applies air pressure to the brake of the
spinning wheel. Doing this transfers engine torque to the wheels that have
better traction.
• If all drive wheels are spinning, ATC limits engine torque which, in turn,
reduces wheel spin to provide improved traction.
When ATC automatically becomes active, the ATC indicator lamp turns on to
alert the operator. The lamp turns off when the wheel(s) stops spinning.
Heavy Mud/Snow Function (If Equipped)

ATC may also include a heavy mud/snow function which allows the operator to
activate ATC when additional traction is needed. This function is activated with
the ATC mode switch which is located on the dashboard. The heavy mud/snow
function increases available traction by increasing permissible wheel spin.
When the operator selects the heavy mud/snow function, the ATC indicator
lamp blinks continuously. The ATC lamp stops blinking when the ATC mode
switch is turned off.
OPERATION 131
Work Brake System

The work brake system is designed to be used when frequent stops are made.
This type of operation, typical in house-to-house refuse collection, consumes
large volumes of air if the spring brake is applied at each stop. The work
brake system uses significantly less air volume than the spring brake system,
improving overall brake system durability.
In addition, the brake system incorporates backup features which apply the
spring brakes in the event of an engine shutdown or significant loss of air
pressure. With the work brake applied, spring brake application will occur if
the engine should be shut off or if a loss of air pressure is detected in the
primary system.
Operating the Work Brake System
Note: Always use the foot brake to bring the vehicle to a complete stop before
applying the work brake.
In normal operation, when the work brake is applied, the transmission will be
shifted into neutral from a forward or reverse gear and both the front and rear
axle service brakes will be applied. When the vehicle shifts to neutral from the
reverse gear, the transmission must be manually shifted back into gear.
WARNING
Loss of vehicle control could occur if the vehicle is in motion when the work
brake is applied (due to wheel lockup on slippery surfaces). In addition, using
the work brake before the vehicle is stopped could throw the operator from
the normal driving position.
Work Brake Application from a Forward Gear

To apply the work brake and place the automatic transmission in NEUTRAL:
1. Bring the vehicle to a complete stop with the foot brake.
2. Lift and rotate the work brake lever clockwise (toward the driver).
3. Lower the lever into the locked (applied) position.
132 OPERATION
To release the work brake and place the automatic transmission back into
the previously selected forward gear:
1. Apply the foot brake.
2. Lift and rotate the work brake lever counterclockwise (toward the
windshield).
3. Lower the lever into the locked (released) position.
Note: Engine speed must be below 900 rpm.
Note: When the work brake is applied, the transmission is automatically shifted
into NEUTRAL, although the transmission shift selector still indicates flashing "2"
gear. Releasing the work brake causes the transmission to shift back into forward
gear. If, however, engine speed is above 900 rpm when the work brake is released,
the transmission will remain in NEUTRAL but the shift selector will still flash "2"
gear. It is then necessary to manually move the shift selector into NEUTRAL, then
back into "2" gear to proceed.
Work Brake Application from a Reverse Gear
Note: When applying the work brake with the transmission in a reverse gear, shifting
out of NEUTRAL is not automatic and must be done manually.
To apply the work brake:

1. Bring the vehicle to a complete stop with the foot brake.
2. Lift and rotate the work brake lever clockwise (toward the driver).
3. Lower the lever into the locked (applied) position.
To release the work brake:

1. Apply the foot brake.
2. Lift and rotate the work brake lever counterclockwise (toward the
windshield).
3. Lower the lever into the locked (released) position.
4. Place the transmission into gear.
OPERATION 133
GOOD DRIVING HABITS
Weight Ratings
Do not overload the vehicle. The gross vehicle weight rating (GVWR) and
gross axle weight ratings (GAWR’s) for a given model may vary due to the
tires, wheels/rims, suspensions, axles and/or frame of a specific vehicle. For
safety and durability reasons, do not exceed the GVWR and GAWR’s listed on
your vehicle’s Safety Certification Label.
Instruments
Glance at the instruments frequently. When problems develop, take prompt
steps to correct them.
Shutting Down the Engine

After a hard run, allow the engine to idle three minutes before shutdown to
stabilize the temperature of all engine parts. Quick shutdowns can cause
engine damage and prevent the turbocharger from being properly lubricated.
For additional options, see “Shutting Down the Engine”, page 139.
General Observation
Make it a habit at stops to walk around your truck and look for fuel, oil and
coolant leaks. Also check the condition of tires, wheel nuts, springs and lights.
Stop trouble before it stops you!
134 OPERATION
STARTING THE VEHICLE
General Information
Before putting the key in the ignition switch, set the parking (spring) brake,
disengage the clutch (if equipped) and put the transmission in NEUTRAL.
CAUTION
Do not engage the starting motor too soon after an incomplete start of the engine,
or the starter may be damaged. Wait at least five seconds before attempting to
restart the engine.
CAUTION
If the engine does not start immediately, limit cranking periods to 30 seconds to
avoid overheating and damaging the starter.
CAUTION
Do not rev the engine at start-up. Turbocharger damage may result because
lubricants need time to establish a film between moving parts.
Push Button Starters

Put the key in the ignition switch. Turn the key clockwise to the first "click"
(about two o’clock position) to activate the instruments. Depress the starter
button and release as soon as the engine starts. Keep the clutch (if equipped)
disengaged until the engine runs smoothly.
OPERATION 135
Air Starters
On chassis equipped with an air starter, make sure that the air pressure gauge
reads a maximum of 120 psi before shutting down and parking for the night.
This will ensure sufficient air pressure for restarting the engine.
WARNING
Make sure clutch is depressed and transmission is in neutral before engaging
the starter! Failure to do so could cause the vehicle to jerk forward
unexpectedly causing serious damage or bodily harm.
Starting MP Engines
Use the following procedure:
1. Crank the engine until it starts.
Note: Do NOT apply the throttle pedal during engine cranking.
CAUTION
DO NOT engage the starting motor too soon after an incomplete start of the engine,
or the starter may be damaged. Wait at least five seconds before attempting to
restart the engine.
If the engine does not start immediately, limit cranking periods to 30 seconds to
avoid overheating and damaging the starter.
DO NOT rev the engine at start-up. Turbocharger damage may result. Lubricants
need time to establish a film between moving parts.
2. After the engine has started, warm the engine until the coolant temperature
reaches normal operating range 77°C to 107°C (170°F to 225°F). Once the
engine reaches this temperature, it can be operated in a normal fashion.
Note: Warm-up time can be reduced by increasing engine idle speed between 1000
and 1200 rpm by either applying the throttle pedal or by using the Electronic Hand
Throttle feature (if equipped).
Note: For bobtail or unloaded applications, the engine may be warmed up by moving
the vehicle with "light" throttle application after only one minute of idle.
136 OPERATION
Priming the MP Fuel System
DANGER
Before working on or inspecting a vehicle, set the parking brakes, place the
transmission in neutral and block the wheels. Failure to do so can result in
unexpected vehicle movement and can cause serious personal injury or death.
DANGER
To avoid potential fire hazard, do not service any part of the fuel system while
smoking or in the presence of flames, sparks or hot surfaces, or when working on
an operating engine. Failure to follow these precautions can result in fire. To
guard against burns from direct contact with hot fuel, wear adequate protective
clothing (face shield, heavy gloves and apron, etc.) when working on a hot engine.
WARNING
DO NOT work near the fan with the engine running. The engine fan can
engage at any time without warning. Anyone near the fan when it turns on
could be seriously injured. Before turning on the ignition, be sure that no
one is near the fan.
OPERATION 137
1. Unlock the hand primer pump by pushing the pump handle in and turning it
counterclockwise.
C0029336
2. Pump the hand primer until the force of pumping increases.
C0029337
Note: When the fuel system is empty, 200 or more pump strokes may be needed
to properly prime the system.
Note: There are NO bleed nipples to be opened in order to prime the fuel system.
3. Lock the hand primer pump by retracting it into the housing and turning
it clockwise.
4. Start the engine and run it at an increased idle speed for approximately 5
minutes to remove any remaining air in the system.
5. Check the fuel system for leaks.
Note: If the engine does not start following this procedure, contact your local MACK
dealer.
138 OPERATION
Engine Warm-Up
CAUTION
Idling the engine unnecessarily for long periods of time wastes fuel and fouls
injection nozzles. Unburned fuel causes carbon formation and oil dilution. NEVER
race an engine during warm-up.
Engine damage can occur if the engine is not warmed up to a minimum

operating temperature of 77°C (170°F) before putting the vehicle into full
operation.
Heavy-duty diesel engines are designed to operate at optimum efficiency
when they are running loaded at (or very near) normal operating temperature,
where efficient combustion takes place. When the engine is operated
unloaded, lightly loaded (i.e., stop-and-go operations, PTO operations, or
periods of extended engine idling) or in cold weather conditions, normal
operating temperature may not be achieved or maintained. As a result, carbon
and/or varnish build-up will occur and lubricating oil will become contaminated
with combustion by-products.
Cold weather operations place added demands on a diesel engine. When
operating in cold climates (particularly in stop-and-go operations, PTO
operations or periods of extended engine idling), minimum operating
temperature must be maintained to prevent engine damage resulting from
valve varnishing and carbon build-up.
Note: Many accessories are available for cold weather operations. Refer to
the Maintenance and Lubrication Manual (21394653) for additional information
concerning cold weather accessories.
Engine Idling
Idling the engine unnecessarily for long periods of time wastes fuel, fouls
injector nozzles and can lead to valve carbon and varnish deposits. Unburned
fuel causes carbon formation and oil dilution. Shut the engine down when
prolonged loading or unloading of cargo is required.
When starting a cold engine, or if the vehicle has been parked and the engine
coolant has fallen well below normal operating temperature, a fast idle speed
of approximately 1200 rpm should be maintained to help the engine warm
up more quickly.
OPERATION 139
Shutting Down the Engine

Standard Shutdown
After a hard run, allow the engine to idle three minutes before shutdown in
order to stabilize the temperature of all engine parts. Quick shutdowns can
cause engine damage and prevent the turbocharger from being properly
lubricated.
CAUTION
Operating the engine below normal operating temperature for extended periods of
time will allow varnish/carbon deposits to build up on the valve stems and guides.
This will cause the valves to stick in the guides after the engine has been shut down
and could result in push rod damage when the engine is restarted. If the engine
has been operated below normal operating temperature for an extended period of
time (and the odor of raw diesel fuel is detected or unburned fuel can be seen at the
exhaust stack), the engine should be operated under "load" until normal operating
temperature is achieved BEFORE shutting down the engine.
On chassis equipped with an air starter, make sure that the air pressure gauge
reads a maximum of 120 psi before shutting down and parking for the night.
This will ensure sufficient air pressure for restarting the engine.
V-MAC IV Shutdown Option: Idle Cooldown

This feature provides a means of cooling down the engine and turbocharger.
If the idle cooldown option is enabled using VCADS Pro MACK Support
Software and the system senses that the turbocharger may be hot, the engine
will not shut down when the vehicle stops, the parking brake is set and the
key switch is turned to the OFF position. This feature allows the driver to lock
the truck and walk away while still providing adequate cooldown. All switched
accessories will then turn off once the engine has stopped. If this option is
set, the engine can be shut down immediately by cycling the key switch or by
pressing the shutdown override switch.
The idle cooldown timer is set to 3.5 minutes as soon as the engine load
exceeds 25%, provided that the engine has been running at least 60 seconds.
After the load drops below 25%, the timer begins counting down. If the key
switch is turned off before the timer expires, the engine will continue to run
until the timer reaches zero.
If a pyrometer is installed, the idle cooldown function will use the pyrometer
reading, shutting the engine down when the temperature drops below 232°C
(450°F), or after 3.5 minutes, whichever comes first.
The default for this option is set at OFF from the factory.
140 OPERATION
Note: The parking brake must be on for the idle cooldown function to work.
Engine Shutdown System (If Enabled)

The engine is protected by a system that prevents engine damage by shutting
down the engine whenever a potentially damaging condition (such as loss of
oil pressure, loss of coolant or engine overheating) is detected. If the system
detects such a condition, a warning indicator light and an alarm will alert the
driver before the engine actually shuts down. Pressing the Shutdown Override
Switch on the instrument panel shortly after the vehicle sounds the engine
shutdown alarm, allows 30 additional seconds of operation. This process can
be repeated several times to safely park the vehicle.
CAUTION
Continuously overriding the shutdown system may result in severe engine damage.
Engine Shutdown Indicator — During normal operating conditions, this

indicator should illuminate as soon as the key switch is turned on. After the
engine is started, it will remain illuminated until engine oil pressure reaches
normal idling range. During shutdown, if the system detects a condition that
could lead to engine failure, the Engine Shutdown indicator will illuminate prior
to engine shutdown.
OPERATION 141
COLD WEATHER OPERATION
DANGER
Do NOT, under any circumstances, use starting fluid (ether) on engine whether or
not equipped with an inlet manifold air heater element. An explosion can occur.
Cold Weather Starting Tips

• Save the batteries. Do not overtax the batteries by cranking the starter for
more than 30 seconds without interruption. Allow about two minutes between
attempts at starting the vehicle; this allows the starter to cool and the batteries
to re-energize.
Note: Always make sure that the battery is fully charged in cold weather.
• Use the correct grade of oil for the prevailing winter temperature.
• Drain the fuel tanks and filters regularly to prevent water accumulation in the
fuel system. This accumulation can freeze in fuel tanks, fuel lines and filters.
WARNING
Do NOT — under any circumstances — add gasoline, alcohol, used oil or
additives with metallic particles to the fuel.
• If the fuel gels and starts clogging filters and small passages, mix a small
percentage of No. 1D fuel (kerosene) with Ultra-Low Sulfer (15 ppm max.)
No. 2D (diesel) fuel.
Note: Adding kerosene is NOT recommended for general use because both
performance and fuel economy will be reduced.
• Refer to the Maintenance and Lubrication Manual (21394653) for additional

cold weather operating information.
142 OPERATION
Engine Block Heaters

An engine block heater works by heating the coolant surrounding the
combustion chambers. Engine heaters are recommended to help combat the
extreme demands of cold weather operating conditions. When the temperature
drops, the engine heater can be plugged in overnight. The location of the
engine heater power receptacle varies according to vehicle design.
C0029338
1. Engine Block Heaters
Engine Heater Benefits

• Eliminates cold weather starting problems.
• Increases engine life significantly by keeping the engine warm and avoiding
costly, excessive idling.
• Prevents external water leaks caused by excessive cold.
• Allows the cab to heat more quickly.
• Reduces the temperature at which ether is required.
• Allows the engine heaters to be activated as soon as the engine is stopped.
OPERATION 143
MOVING THE VEHICLE — GENERAL

INFORMATION
Braking
Avoid sudden stops. Constant sudden stops may negatively affect braking
performance and driving parts. When slowing, leave the clutch (if equipped)
engaged as long as possible to use the braking effect of the engine.
CAUTION
When using the braking effect of the engine, final gear selection is critical. If gear
selection is too high, the vehicle will buck which could cause loss of control.
Engine Temperature
Before entering high-speed traffic conditions, allow the engine to reach normal
operating temperature. A normal operating range is between 77°C and 104°C
(170°F and 220°F) for stationary vehicles.
1. To move the vehicle, begin by starting the engine and waiting until it
reaches normal operating range (see Coolant Temperature Gauge in the
Instrument Panel section for the correct engine temperature).
2. Shift transmission into the desired gear. Refer to the Transmission Shifting
Instructions section for shifting instructions (including the proper starting gear).
3. Release the parking brake.
CAUTION
If the Parking Brake indicator light is on, do NOT attempt to move the vehicle or
driveline damage may result.
4. Apply the accelerator enough for the engine to move the load.
Right-Side Operation
Note: Speed is restricted to second gear when operating the vehicle from the
right-hand side.
144 OPERATION
— Stop the vehicle.

— Put the transmission in NEUTRAL.
— Set the parking brake.
— Go to the right side of the vehicle.
— Flip the switch to the right.
OPERATION 145
TRANSMISSION SHIFTING INSTRUCTIONS
CAUTION
Never coast with the transmission in neutral. Never coast with the clutch depressed.
ALLISON TRANSMISSION SHIFTING INSTRUCTIONS

For additional information, refer to your Allison transmission manual supplied
with your vehicle.
Allison 4500 RDS, WTEC III Controls and 4th Generation Controls
Shifting Instructions with Allison Transmission Electronic Control
WARNING
Do NOT allow your vehicle to coast in NEUTRAL. There is no engine braking
and you could lose control. Coasting can also cause severe transmission
damage.
WARNING
If it is necessary to leave the vehicle, even momentarily, while the engine is
running, put the transmission in NEUTRAL. Be sure the engine is at low idle
(500–800 rpm). Apply the parking brakes and emergency brake and make
sure they are properly engaged before exiting the cab. Chock the wheels and
take any other steps necessary to keep the vehicle from moving.
146 OPERATION
CAUTION
The Allison 4500 RDS transmission will not operate in lockup mode when an active
ABS fault exists. Prolonged operation of the transmission while an ABS code is
active can overheat the transmission oil.
Note: TranSynd™ and the most current specification DEXRON® fluids are
recommended for all RDS transmission applications. For more information, please
refer to the applicable Allison transmission operator’s manual provided with your
vehicle.
OPERATION 147
Use this to back the vehicle. Completely stop the vehicle

and let the engine return to idle before shifting from forward
R to reverse or from reverse to forward. The reverse warning
signal sounds when this gear is selected. The digital display
will display R when reverse is selected.
Use neutral when starting the engine, to check vehicle
accessories, and for extended periods of engine idle
operation (longer than five minutes). For vehicles equipped
with the pushbutton selector, neutral is selected by the ECU
N during start-up. If the vehicle starts in any range other than
neutral, seek service immediately. Neutral is also used during
stationary operation of the power takeoff (if equipped). The
digital display will show N when neutral is selected. Always
select neutral before turning off the vehicle engine.
The transmission will initially attain first-range when drive is
selected. As vehicle speed increases, the transmission will
upshift automatically through each range. As the vehicle
D
slows, the transmission will downshift automatically through
each range. The digital display will show the highest range
available in D (drive).
Occasionally, road, load or traffic conditions will make it
desirable to restrict automatic shifting to a lower range.
6 (When conditions improve, the gear selector should be
5 returned to the normal drive position.) These positions also
4 provide greater engine braking for going down grades (the
3 lower the range, the greater the braking effect). Note that
2 even if a lower range is selected, the transmission may not
downshift until vehicle speed is reduced. The digital display
shows the range selected.
Use this gear when pulling through mud or deep snow,
maneuvering in tight spaces, or while driving up or down
1 steep grades. First-range provides the vehicle with its
maximum driving torque and engine braking effect. Push the
down arrow until first-range appears in the select window.
The 4500 RDS shift selector is an electronic control unit with membrane-type
push-button switches.
In addition to the R, N, D, Up arrow and Down arrow push buttons, the 4500
RDS shift selector incorporates a MODE button, which allows the driver to
enable a secondary shift schedule or other special function.
When you select and depress the desired operating range, a slight click will
be felt and a tone will sound.
In D (drive), selection of a specific range can be accomplished by pressing the
Up or Down arrow buttons to reach the desired operating range.
148 OPERATION
C0029635
Status Lights
Check Trans Light — Illumination of this indicator notifies the driver of a
problem with the transmission system and automatically takes action to
protect the driver, vehicle and transmission.
For 4500 RDS transmissions, when the Electronic Control Unit (ECU) detects
a problem condition, the ECU will restrict shifting, turn on the CHECK TRANS
light on the instrument panel, and register a diagnostic code.
CAUTION
Applying parking brakes or work brake (if equipped) from the right side of the truck
while in DRIVE will force the transmission into NEUTRAL.
OPERATION 149
Transmission Module Location

The Electronic Control Unit (ECU) is located in the compartment below the
left-side driver seat.
Note: Shifting is restricted to second gear when the vehicle is being operated from
the right-hand driving position.
Note: For body builders, applicable connections have been reduced to one plug which
is located in the compartment below the left-side driver’s seat.
150 OPERATION
AXLES
Rear Axles Other Than MACK

Please refer to the operators manual provided with your vehicle for axles
other than MACK.
MACK Rear Axles

Mack Trucks, Inc. provides axle housings in three capacity classifications:
• Medium Duty
• Heavy Duty
• Extra-Heavy Duty
To deliver the appropriate amount of torque to the driving wheels, MACK

offers dual-reduction carriers in a variety of ratios.
Mack Trucks, Inc. offers a large variety of four-wheel-drive tandem axles with
top-mounted, dual-reduction carriers (for straight line through drive). Carriers
are also available in a large number of ratios.
All four-wheel-drive tandem carriers are available with the MACK inter-axle
power divider third differential (with or without a power divider lockout).
MACK rear axles are designed so the entire load is carried by the axle housing
(through the wheel bearings mounted on the housing spindle). The rear axle
shafts are either free-splined (both ends) or integral flange type. Both types of
axle shafts can be removed without removing or disturbing the rear wheels.
To avoid excessive tire wear, proper maintenance must be practiced and rear
axle tires must be matched.
CAUTION
The maximum safe operating oil temperature for a MACK rear axle is 121°C
(250°F) for mineral-based oil, and 148°C (300°F) for synthetic-based oil.
Continued operation with oil above this temperature will result in rapid
deterioration of the oil’s lubricating properties and is NOT recommended.
OPERATION 151
Inter-Axle Power Divider Lockout (If Equipped)

The MACK power divider can be rendered inoperative, during short periods of
poor traction, using a power divider lockout. When the power divider lockout
is engaged, both axles are locked together (in positive through-drive) for
maximum traction with no differential action between axles. It is not necessary
to stop the vehicle to engage the power divider lockout. The lockout may be
engaged while the vehicle is moving at less than 48 Kph (30 mph), as long as
the wheels are not spinning.
CAUTION
Do not engage the power divider lockout if the wheels are spinning.
Note: Even when no traction is available at the spinning wheel, the driver can
"feather" the brakes (apply the brakes slightly), creating enough resistance at that
wheel to allow power to the axle with traction. Feathering brakes should not be done
with power divider lockout engaged.
Note: For vendor axles, see the vendor manual furnished with the vehicle.
Engaging the Power Divider Lockout

Normally, the Power Divider switch is in the OUT (disengaged) position. In
poor traction conditions, it may be necessary to provide positive through-drive
to both axles by flipping the switch to the locked (engaged) position.
1. Push switch to engage.
2. Momentarily release the accelerator pedal to allow the shift to take place,
then drive through the slippery area.
Note: A lockout indicator lamp will remain lit as long as the lockout is engaged. This
is to remind the driver to release the lockout as soon as normal traction is regained.
3. When driving conditions permit, unlock the power divider by moving the
Power Divider switch back to the OUT (disengaged) position. Then release
the accelerator pedal momentarily (to shift out of the locked position) and
drive as usual.
152 OPERATION
CAUTION
Do NOT (under any circumstances) engage or disengage the lockout while the
drive wheels are actually slipping or spinning; clashing between the lockout sliding
clutch and the outer cam may result.
LIFTABLE AXLES
Liftable (tag and pusher) axles are used to distribute weight evenly across
the chassis so maximum payload can be accommodated with various state
weight regulations.
CAUTION
Do NOT overload the chassis. Observe the Gross Vehicle Weight rating found on
the Safety Certification Label.
WARNING
Do NOT use the tag or pusher axles when the vehicle is empty.
CAUTION
Do NOT lower the tag or pusher axles if the vehicle is moving at speeds above 8
kph (5 mph).
Setting Axle Air Pressure — Tag and pusher axle load is regulated by air
pressure. Proper air pressure adjustment is important for maintaining proper
steering control and avoiding axle overload.
OPERATION 153
Axle air pressure should be set to provide proper weight distribution across the
chassis and to conform to local weight regulations. In general, a setting of 60
to 70 psi is adequate for most applications, but an accurate setting should be
determined by weighing the axles and adjusting the air pressure accordingly.
Adjustable air regulators are located inside the cab to adjust tag and pusher
axle air pressure. Pressure is regulated by turning the knob until the proper
pressure, as indicated by the accompanying pressure gauge, is reached. Turn
the air regulator knob clockwise to increase pressure, or counterclockwise
to decrease pressure.
154 OPERATION
Extended Idling and Aftertreatment System

Conditioning
Extended idling performed on this vehicle equipped with an exhaust
aftertreatment system should be carried out at a low engine idle speed. There
is no benefit to using a raised engine idle speed for extended idling. The
only exception is for active PTO operation. Utilizing an engine speed above
1300 rpm is recommended for vehicles which perform extended idling with an
active PTO.
During periods of extended idling, normally greater than 8hrs, the conventional
DPF system needs to perform a routine conditioning cycle. The conditioning
cycle is controlled by the Engine ECU and will start and stop automatically
as needed. The ATS conditioning is required to maintain normal exhaust
aftertreatment system function and should not be stopped. ATS conditioning
will not occur onTRU DPF systems.
During these events the engine speed will increase to approximately
1050–1400rpm, for non-PTO operation, in order to complete the exhaust
aftertreatment conditioning cycle. Exhaust temperatures will also elevate
slightly but remain much lower than those reached during regeneration and
present no danger.
If a compatible driver display is available a message will be displayed when
the conditioning cycle is in progress. The message indicated in the driver’s
display will be "ATS Conditioning in Progress, No Action Required." If no driver
display is available there will be no indication of an ATS conditioning event
except for the automatic increase in engine speed.
Mack, US10 Emissions Solution 155
DIESEL PARTICULATE FILTERS

Your new MACK chassis is equipped with a 2010 emission compliant
engine and an exhaust aftertreatment system which includes a Diesel
Particulate Filter (DPF), which reduces soot and particulate emissions into the
atmosphere. Vehicles equipped with a Diesel Particulate Filter require the
use of EO-O Premium Plus (or VDS-4) specification high performance diesel
engine oil and Ultra Low Sulfur Diesel (ULSD) fuel.
CAUTION
Use of diesel fuel other than ULSD and engine oils other than EO-O Premium
Plus (or VDS-4), will adversely affect performance, efficiency and durability of
the DPF system and the engine, to the point where the engine may not run at all.
Manufacturers warranties will also be rendered void due to usage of improper fuel.
Unapproved fuel additives (including engine oil) are NOT permitted.
Mack Trucks, Inc. offers two different types of DPF systems:

• Conventional DPF (passive regeneration and parked regeneration)
Thermal Regeneration Unit (TRU) DPF (moving regeneration and parked
regeneration)
156 Mack, US10 Emissions Solution
As well as two different mounting styles:

1. MACK Vertical Back-of-Cab DPF both conventional DPF or conventional
DPF or TRU
2. Mack-Cap DPF, which is a space saying unit that is mounted inside the
frame (conventional only)
C0029353
A Diesel Particulate Filter (DPF) takes the place of the standard muffler. The
DPF is used to meet EPA requirements to help reduce soot and particulate
emissions into the atmosphere. The particulates are removed by collecting in
the DPF unit, where they are eventually oxidized with passive regeneration
or active regeneration of the filter. The electrical system and exhaust
aftertreatment system of the vehicle will determine when regeneration
is required. Mack Trucks, Inc., uses two exhaust aftertreatment system:
conventional and TRU
Conventional exhaust aftertreatment systems use passive-active regeneration.
The passive regeneration process oxidizes the particulates captured in the
DPF while the vehicle is in operation. An oxidation catalyst raises the exhaust
temperature to approximately 260°C (500°F), the temperature at which a
chemical reaction takes place to oxidize the soot (passive regeneration).
Conventional exhaust aftertreatment systems are used in highway and certain
vocational applications. TRU exhaust aftertreatment systems are used mainly
in refuse collection applications.
Depending on how the vehicle is set up, regeneration can occur while the
vehicle is being driven (referred to as a "moving" regeneration) or when the
vehicle is parked and idling (referred to as a "parked" regeneration).
CAUTION
When active regeneration occurs (with either system), the temperature of the
exhaust will be elevated. DO NOT park the vehicle with the exhaust outlet under
low hanging overhead flammable objects such as trees, awnings, etc., that could be
damaged by elevated exhaust temperatures. DO NOT remove the diffuser.
CAUTION
If the vehicle is in a location that may be hazardous when an active regeneration
begins (i.e., in close proximity to flammable materials or gases), the regeneration
should be stopped by pushing the DPF switch to the "Stop Regeneration" position.
If an active regeneration is stopped by the vehicle operator, it should be initiated at
a later time when the vehicle is in a safe location. However, if an active regeneration
is stopped too many times, the vehicle must be taken to a MACK service facility.
The service facility will use a service tool to manually initiate the regeneration.
WARNING
For chassis equipped with a heated dump body, be aware that temperature
around the area where the exhaust enters the body, as well as the product
contained in the body, may be elevated, particularly during DPF regeneration.
Exhaust Aftertreatment System
LEU Standard System View
W2031562
1. Selective Catalytic Reduction (SCR) ultra-pure water. Urea is a compound

Catalyst of nitrogen that turns to ammonia when
heated. It is used in a variety of industries,
2. Aftertreatment DEF Dosing Unit perhaps most commonly as a fertilizer in
3. Aftertreatment Diesel Particulate agriculture. The fluid is non flammable,
Filter (DPF) and is not dangerous when handled as
recommended. However, it is highly
4.Aftertreatment DEF Tank corrosive to certain metals, especially
copper and brass. Read the separate
Diesel Exhaust Fluid (DEF) is a reactant section concerning the handling of DEF
that’s key to the SCR process. It’s a solution.
nontoxic, ultra-pure solution of urea and
Safety Information
Mack utilizes the use of a Diesel
Particulate Filter (DPF) and Selective DANGER
Catalytic Reduction (SCR) to meet
EPA2010 emissions. The system is Exhaust gases and components can
designed to require very little driver be at extremely high temperatures
interface to maintain correct operation. during regeneration. When parking the
The technology utilizes a passive vehicle, keep away from any flammable
regeneration; requiring no fuel to be materials, vapors, or structures.
injected to clean the DPF. In EPA2007 an
active regeneration (fuel was injected) was
required to clean out the DPF producing DANGER
very high exhaust outlet temperatures.
Certain vocational duty cycles will The temperature of the exhaust system
require the use of fuel and/or a parked components during the regeneration
regeneration to clean out built-up soot in process can exceed 350 degrees C
the particulate filter. Exhaust temperatures (660F). The exhaust gas leaving the
will increase during a parked regeneration. system can reach 505 degrees C
When parking the vehicle to perform a (930F). Various factors (including
parked regeneration keep away from any ambient temperature and duration of the
flammable materials, vapors or structures. regeneration process) determine when
these components will return to normal
operating temperature after regeneration
has completed. Be extremely careful
around these hot components. Contact
with these components can result in
serious personal injury.
Exhaust Aftertreatment System Components

and
Selective Catalytic Reduction (SCR)

Selective Catalytic Reduction (SCR) is an aftertreatment systems, called diesel
emissions-reduction technology with the particulate filters, to control emissions of
ability to deliver near-zero emissions of another pollutant, soot (also known as
nitrogen oxides (NOx), a smog-causing particulate matter or PM).
pollutant and greenhouse gas. SCR’s
performance has been proved in millions SCR works by injecting Diesel Exhaust
of miles of real-world trucks in other Fluid (DEF) into the exhaust. DEF is a
countries, as well as in long-term field solution of ultra-pure water and urea. DEF
tests in the U.S. works with the heat of the exhaust and a
catalyst to convert NOx into nitrogen and
SCR reduces NOx emissions to very low water vapor - two harmless and natural
levels, while at the same time delivering components of the air we breathe. The
excellent fuel economy and reliability. end result is cleaner air, excellent fuel
The system doesn’t change the design efficiency and a reliable emissions control
or of the basic engine. Rather, SCR is system for today’s modern diesel engine.
an aftertreatment system which converts
NOx in the exhaust stream into harmless
gases. Modern diesels already use exhaust
W2031651
System Operation 5 Aftertreatment Diesel Particulate Filter

1 Diesel engine optimized for high (DPF).
performance, low particle emissions 6 In the SCR catalyst, nitrogen oxides
and low fuel consumption. are transformed into harmless nitrogen
2 Aftertreatment DEF tank gas and water.
3 The Aftertreatment Control Module 7 The system notifies the driver when it
(ACM) continuously monitors and is time to refill tank with DEF.
adjusts the DEF injection rate.
4 DEF is injected into the exhaust gases
in between the Aftertreatment DPF (5)
and the SCR catalyst (6).
The advantage of using DEF is that it enables the engine to use less EGR -- and
higher oxygen levels -- for better combustion, while meeting the EPA NOx emissions
requirement. By using DEF, we avoid the disadvantages of increasing EGR to massive
levels. This results in better fuel economy from your Mack engine.
W2055490
Vertical SCR, side inlet
CAUTION
Do not put diesel fuel in the
Aftertreatment DEF tank. Diesel
fuel, if sprayed into the hot exhaust
along with the DEF, could ignite
explosively causing a fire resulting
in personal injury or damage to the
exhaust system.
W3036787
Diesel Exhaust Fluid (DEF)

Diesel Exhaust Fluid (DEF) is a reactant urea. Use of fluids other than API certified
that’s key to the SCR process. It’s a Diesel Exhaust Fluid will compromise
nontoxic, ultra-pure solution of urea and aftertreatment system performance,
ultra-pure water. Urea is a compound increase emissions, and may impact your
of nitrogen that turns to ammonia when product warranties. Never dilute DEF
heated. The fluid is non flammable, with water or any other fluid.
and is not dangerous when handled as It is recommended that DEF not be stored
recommended. However, it is highly in extreme hot or cold conditions, or for
corrosive to certain metals, especially prolonged periods. Follow the instructions
copper and brass. Read the separate for proper storage and handling as
section concerning the handling of DEF indicated on the container or provided
solution. with the purchase.
Use only Diesel Exhaust Fluid that is
Note: Agriculture mixtures are not pure
clearly labeled as meeting ISO-22241
standards, and certified by the American enough for use in the SCR system and
Petroleum Institute. The container must impurities in the solution will comprise
display the API certification seal. Never the SCR system.
use agricultural or industrial grade
Diesel Exhaust Fluid (DEF) Handling

When handling DEF solution, it is
important to prevent contact with CAUTION
electrical connections. There is a risk that
the DEF will cause oxidation that cannot When detaching hoses and components,
be removed. Water or compressed air do not spill DEF on disconnected
do not help, since DEF quickly oxidizes or unsealed connectors. If DEF is
certain metal. If a disconnected connector spilled on a disconnected or unsealed
comes into contact with the DEF solution connector, the connector must be
it must be replaced immediately to prevent replaced immediately.
the DEF solution from creeping further
into the copper wiring.
Things to know about spilled Diesel Exhaust Fluid (DEF)
If DEF solution comes into contact with the skin: rinse with plenty of water and
remove contaminated clothing.
If DEF solution comes into contact with the eyes: rinse for several minutes and call
for medical help if necessary.
If inhaled: breathe fresh air and call for medical help if necessary.
Do not allow the DEF solution to come into contact with other chemicals.
The DEF solution is not flammable. If the DEF solution is exposed to high
temperatures, it breaks down into ammonia and carbon dioxide.
The DEF solution is highly corrosive to certain metals, including copper and brass.
If the DEF solution is spilled onto the vehicle, wipe off the excess and rinse with
water. Spilled DEF solution can form concentrated white crystals on the vehicle.
Rinse off these crystals with water.
Note: Do not flush DEF spillage into the

normal drain system.
Diesel Exhaust Fluid( DEF) Consumption

DEF consumption is related to fuel completely, vehicle power will be reduced.
consumption. A highway truck may travel When the DEF tank is refilled, the engine
225–300 miles or more on one gallon of will resume normal power.
DEF. A gauge much like a fuel gauge will
Note: DEF tanks are sized for a two to
indicate the level of DEF in the tank. A
DEF low-level warning will activate when one fuel to DEF ratio in order to meet US
DEF is low. If a driver runs out of DEF 2010 requirements.
Diesel Exhaust Fluid (DEF) Availability

DEF will be available in 2.5-gallon carry DEF.
containers, 55-gallon drums, 275 gallon DEF will freezes at –11 degrees C (12
IBC and in bulk storage for fleet locations, F). DEF needs to be protected from
truck stops and dealerships. All major extended periods of severe cold. For more
truck stops, dealers and distributors will information on DEF and availability please
visit the website www.Mackscr.com or please contact Mack One-Call at

1–800–866–1177.
Aftertreatment Diesel Particulate Filter (DPF)
exhaust smoke is visible during engine

CAUTION operation, this indicates a problem with
the exhaust aftertreatment system. Take
Use of diesel fuel other than ULSD and the vehicle to an authorized Mack Truck
engine oils other than EO-O Premium dealer immediately.
Plus (or VDS-4), will adversely Vehicles equipped with a 2010 emission
affect performance, efficiency and compliant engine have an exhaust
durability of the Aftertreatment DPF aftertreatment system which includes
system and the engine, to the point a Selective Catalytic Reduction (SCR)
where the engine may not run at system and a Conventional or TRU
all. Manufacturers warranties can Aftertreatment Diesel Particulate Filter
also be rendered void due to usage (DPF). The Aftertreatment DPF takes
of improper fuel. Unapproved fuel the place of the standard muffler, and it
additives (including engine oil) are reduces particulate emissions into the
NOT permitted. Blends of No. 1D atmosphere. Soot and other particulate
and No. 2D grades of ULSD are matter are collected by a filter where it is
recommended and allowable for cold eventually oxidized using a regeneration
weather operations. process. Vehicles equipped with a
Aftertreatment DPF require the use
The exhaust aftertreatment system of EO-O Premium Plus (or VDS-4)
virtually eliminates exhaust smoke. White specification high performance diesel
exhaust vapor (water condensation) may engine oil and Ultra Low Sulfur Diesel
be visible during a cold start. If black (ULSD) fuel.
Aftertreatment Control Module (ACM)

The ACM also monitors the following
values in the exhaust aftertreatment
system:
• Aftertreatment DEF Dosing Pressure
• Aftertreatment DEF Tank Temperature
• Aftertreatment DEF Tank Level
• Aftertreatment DPF Inlet/Outlet
Temperature
• Aftertreatment DEF Tank Level Sensor
W2029917
• Aftertreatment DPF Differential
Pressure
The ACM controls the following
components in the exhaust aftertreatment • NOX Sensors
system:
The ACM is a stand alone module.
• Aftertreatment DEF Dosing Unit Depending on your configuration it may
be mounted as part of the DEF tank (as
• Aftertreatment DEF Tank Heater Valve
shown above) or on a bracket near the
• Aftertreatment DEF Line Heaters DEF tank.
• Aftertreatment DEF Pump
• Aftertreatment DEF Return Valve
Exhaust Aftertreatment System

Aftertreatment DPF Regeneration

DPF Smart Switch– This is a three-position switch where the middle position
is neutral.
C0029148
DPF Smart Switch
1. Upper Position – Regeneration 3. Down Position – Inhibit Position (if

Position equipped)
2. Middle Position – Neutral Position
CAUTION
During the Aftertreatment DPF Regeneration, the exhaust gas temperature will
be elevated. DO NOT park the vehicle with the exhaust outlet near flammable
objects such as trees, awnings, etc. that could be damaged by elevated exhaust
gas temperatures.
CAUTION
If the vehicle is in a location that may be hazardous when DPF Regeneration
begins (i.e., in close proximity to flammable materials or gases, inside tunnels,
parked under flammable objects, etc.), the DPF Regeneration should be stopped
(if equipped). If DPF Regeneration is stopped by the vehicle operator, it must
be initiated at a later time when the vehicle is in a safer location. Regenerations
that are stopped and never restarted at a later time, however, will require that the
vehicle be taken to an authorized Mack Truck dealer to have the Aftertreatment
Regeneration manually started with special service tools.
Note: During vehicle operation, idle speed may increase when the vehicle is stopped
at a traffic light to maintain proper Aftertreatment DPF Regeneration conditions.
Parked Regeneration
When parked regeneration is needed, an icon at the top of the DPF Smart switch will
illuminate to notify the vehicle operator. The DPF Smart switch allows the vehicle
operator to either stop or start regeneration. (Certain conditions must be met, however,
before regeneration can be manually started.)
Parked regeneration allows the operator to start and/or stop the regeneration
manually when the vehicle is parked and the engine is idling. The operator is
notified that a regeneration is needed when the icons on the DPF Smart switch
illuminate. The operator should perform the regeneration as soon as possible.
Please refer to the instructions below on how to use the DPF Smart switch for
parked regenerations.
1. Move the vehicle to a safe location, apply the park brake and allow the
engine to idle.
WARNING
When a regeneration is in process, the temperature of the exhaust will be
elevated. DO NOT park the vehicle with the exhaust outlet under low hanging
overhead flammable objects such as trees, awnings, etc., that could be damaged
by elevated exhaust temperatures. DO NOT attempt to regenerate inside a
garage or enclosed area if the tail pipe is attached to an exhaust ventilation
system as the hose material may not be rated for the high temperature.
2. Press and hold the top part of the DPF Smart switch momentarily to initiate
the regeneration.
3. During regeneration, the icons on the switch will shut off. The HEST
indicator on the instrument cluster will light up to notify of high exhaust
temperatures.
4. For aftertreatment DPF filter systems, the engine speed may ramp as
high as 1,250 rpm.
5. Parked regeneration will take between 45 to 60 minutes to complete.
6. After regeneration has completed and the exhaust temperature has
returned to normal, the HEST indicator will shut off.
7. To stop regeneration, press the switch down to the inhibit position (if
equipped). When the bottom of the switch is illuminated, regeneration is
stopped. The switch will remain locked in this position and the light will stay
illuminated. The driver has the option of stopping a regeneration if the vehicle
is in an area where elevated exhaust temperatures will pose a hazard (i.e.,
tunnel, under trees, in an area where there is flammable material, etc.).
Note: The HEST lamp will remain On if it comes On during the regeneration, and
remain On until the exhaust temperature returns to normal.
CAUTION
Failure to perform a regeneration in a timely manner after notification may result
in engine derate, a clogged DPF, damage to the DPF and engine shutdown.
DANGER
During the regeneration process, the temperature of the exhaust gases will be
elevated. DO NOT park or stop for an extended period under low hanging
overhead flammable objects such as trees, awnings, structures, etc., that could
be damaged by elevated exhaust temperatures. Further, if the vehicle is being
operated in an area where flammable vapors exist, the regeneration process must
be interrupted. Failure to heed these cautions may result in fire or explosion
causing serious personal injury or death.
Note: If the vehicle is in a location that may be hazardous when an active regeneration
begins (i.e., in close proximity to flammable materials or gases), the regeneration
should be stopped by pushing the DPF switch to the "Stop Regeneration" position.
If an active regeneration is stopped by the vehicle operator, it should be initiated at a
later time when the vehicle is in a safe location. However, if an active regeneration is
stopped too many times, the vehicle must be taken to a MACK service facility. The
service facility will use a service tool to manually initiate the regeneration.
WARNING
The temperature of the exhaust system components during the regeneration
process 350 degrees C (660 F). The exhaust gas leaving the system can reach
505 degrees C (930 F). Various factors (including ambient temperature and
duration of the regeneration process) determine when these components will
return to normal operating temperature after regeneration has completed.
Be extremely careful around these hot components. Contact with these
components can result in serious personal injury.
CAUTION
When the inhibit position is pressed, the switch will remain in a locked position. It
is important, therefore, to immediately set the switch back to the neutral position
when safe to do so. Failure to set the switch back to the neutral position may result
in an engine derate, clogged diesel particulate filter or damage to the filter.
DPF INHIBIT ROAD SPEED LIMITING (RSL)

The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen)
position by the driver (if equipped). If the DPF Smart Switch remains in the
locked position, the following vehicle speed limiting will occur:
1 Vehicle Moving. If vehicle is moving with the DPF Smart Switch in the locked
(DOWN) position, the vehicle speed will decrease down to 16 kph (10 mph) below
the current speed until the driver releases the switch back to the neutral (MIDDLE)
position.
2 Vehicle Stationary and then Moving. If the vehicle is stationary with the DPF
Smart Switch in the locked (DOWN) position and the driver then begins to move
the truck, the vehicle speed will be limited to 16 kph (10 mph) until the driver
releases the switch back to the neutral (MIDDLE) position.
Refer to the Exhaust Aftertreatment for additional Aftertreatment DPF

System Information sun visor label information.
W8056653
Driver Warnings and On Board Diagnostics

(OBD)
On Board Diagnostics (OBD)

Beginning with your US 2010 compliant the vehicle operator to any detected need
Vehicle, On Board Diagnostics (OBD) is for an emission related repair. When the
introduced. This is very similar to the On systems detects a needed repair to an
Board Diagnostics (OBD) system that has emissions related component it activates
been required on passenger cars for many the Malfunction Indicator Lamp (MIL).
years.
The list of emissions related components
On Board Diagnostics (OBD) is a can be found in the Warranty and
system that monitors the functions of Maintenance section of this manual.
emissions related components and alerts
Instrument Cluster
The aftertreatment icons are located in the instrument cluster per the following images.
LEU Instrument Cluster
W3031622
A Left Side Indicator Set B Right Side Indicator Set
1. Malfunction Indicator 2. CHECK Lamp 3. Aftertreatment DEF

Lamp (MIL) Low Lamp
4. High Exhaust 5. Aftertreatment DPF 6. Aftertreatment DEF
Temperature (HEST) Regeneration Required Tank Gauge
Lamp Lamp
Instrument Cluster Icons

Aftertreatment icons are displayed on temperature during a moving regeneration.
the instrument cluster. There are 3 When the HEST icon is illuminated, do
aftertreatment icons: not park or operate the vehicle near people,
• Aftertreatment DPF Regeneration or any flammable materials, vapors, or
structures.
Required
• High Exhaust System Temperature
(HEST)
• Aftertreatment DEF Tank Low Level
Indicator
The Aftertreatment DPF Regeneration
Required icon flashes when the Diesel
Particulate Filter is becoming full/overfull W3007444
and regeneration is needed.

High Exhaust System Temperature
(HEST) Icon
W2029416
W3007445
Aftertreatment DEF Tank Low Level
Aftertreatment DPF Regeneration Indicator (DEF)
Required Icon The Aftertreatment DEF Tank Low Level
The High Exhaust System Temperature Indicator icon illuminates when the fluid
icon illuminates when a parked level is low. It also Flashes when the level
Aftertreatment DPF Regeneration is becomes critically low.
initiated. It also indicates high exhaust gas
Malfunction Indicator Lamp (MIL)
W3031200
MIL Lamp
• MIL indicates government Regulation • Lamp may remain active after repair
On Board Diagnostics (OBD) faults until system confirms repair
Aftertreatment DEF Tank Level - Driver Warning

& Inducement
Aftertreatment DEF tanks are sized to The vehicle instrument cluster has a
have no less than 2 times the diesel fuel Aftertreatment DEF Tank Level Gage
tank mileage or hour range
Triggers Aftertreatment Amber Warning Inducement
DEF Tank Low Lamp
Level Indicator
>12% None None None
Aftertreatment
DEF Tank Level
Gauge
<=12% None None
Aftertreatment
DEF Tank Level
Gauge W2029416
0% Aftertreatment None 25% torque

DEF Tank Level reduction
Gauge
W2029415
0%Aftertreatment None 8 km/h (5 mph)

DEF Tank Gauge Road Speed Limit
Insufficient DEF (RSL)
Pump Pressure
Diesel Fuel
Refueling >15%
W2029415
Note: Vehicle has to be stationary before

8 km/h 5 mph RSL becomes active.
Aftertreatment DEF Quality - Driver Warning &

Inducement
Triggers Aftertreatment Amber Warning Inducement
DEF Tank Low Lamp
Level Indicator
Good DEF Quality None None None

Poor DEF Quality None None
DTC Initial
Detected
W3031623
Poor DEF Quality None 25% torque reduction

DTC Initial
Detected + 10
hours
W3031623
Poor DEF Quality None 8 km/h (5 mph) Road

DTC Initial Speed Limit (RSL)
Detected + 20
hours Diesel Fuel
Refueling >15% W3031623
Temporary Exit None 25% torque reduction

from 5 mph
Inducement
W3031623
Note: Vehicle has to be stationary before

8 km/h (5 mph RSL) becomes active.
Exit conditions for DEF Quality "5 mph road speed limit" Inducement:
First Restart: Return to 25% torque reduction until proper DEF quality evaluation.
If poor DEF quality is detected during the next monitoring cycle then and 5 mph
resumed after vehicle stationary for 20 minutes. After the second restart a Service
Tool is required to exit the 8 km/h (5 mph) RSL.
Misfilling Diesel or Aftertreatment DEF Tanks

Although diesel fuel and Aftertreatment • Costly repairs
DEF caps are clearly labeled and filler
necks and nozzles are different accidents Results of misfilling Diesel in
can happen. Aftertreatment DEF Tank
Contamination of fluids by- misfilling of

• Aftertreatment SCR system may be
diesel or DEF in the wrong tank may result damaged by Diesel
in vehicle malfunction. • SCR Catalyst may be damaged by
Results of misfilling DEF in Diesel Tank diesel (chemical damage)
• Engine may run poorly or not at all • Emissions may be non-compliant
• Injectors may be damaged • On Board Diagnostic (OBD)

Diagnostic Trouble Codes (DTC)
• Exhaust system corrosion may
• Costly repairs
occur between turbocharger and
Aftertreatment DPF
• On Board Diagnostic (OBD)
Diagnostic Trouble Codes (DTC)
SCR Tampering - Driver Warning & Inducement

1. Disconnected Aftertreatment DEF tank 4. Disconnected Aftertreatment DEF
level sensor pump
2. Blocked Aftertreatment DEF line or 5. Disconnected SCR wiring harness
dosing unit
3. Disconnected Aftertreatment DEF 6. Disconnected NOx Sensor
dosing unit
Triggers Aftertreatment Warning Lamp Inducement

DEF Tank Low
Level Indicator
No Tampering None None None
Tampering DTC None None
Pending
W3031623
Tampering DTC None None

Confirmed
W3031623
Tampering DTC None 25% torque

Initial Detected + reduction
10 hour
W3031623
Tampering DTC None 8 km/h (5 mph)

Initial Detected + road speed limit
40 hours Diesel
Fuel Refueling
>15% W3031623
Note: Operator can not override the 8 Note: Vehicle has to be stationary before
km/h 5mph road speed limit. 8 km/h (5 mph RSL) becomes active.
Warranty and Maintenance
Exhaust Aftertreatment System Maintenance

The vehicle must be taken to an authorized
Mack Truck dealer to remove the ash from
the Aftertreatment Diesel Particulate Filter
and clean the Aftertreatment Doser.
Engine Maintenance Intervals

Component Interval
Every oil change. Under certain
conditions (for example, irregular
Fuel Filter Change fuel quality), the fuel/water separator
filters may require more frequent
replacement.
Control lamp indication or 24
Air Cleaner Change
months, whichever comes first
Valve and Injector Lash
200 000 km (125,000 miles) or 12
adjustment , MP7 and Initial Adjust
MP8
Injector Lash Adjustment , Every 400 000 km (250,000 miles) or
Adjust
MP7 and MP8 24 months, whichever comes first
Aftertreatment DPF Ash 400 000 km (250,000 miles) or 4,500
Clean
Cleaning hours, whichever occurs first
240 000 km (150,000 miles) or 4,500
Aftertreatment Doser Clean
hours, whichever occurs first
First change at 161 000 km (100,000
miles) 3200 hours or 3 years
Aftertreatment Diesel
Change whichever occurs first, 241,000 km
Exhaust Fluid (DEF) Filter
(150,000 miles) 4800 hours or 3
years there after
Aftertreatment Diesel
280 000km (175,000 miles) or 12
Exhaust Fluid (DEF) Filler Clean
Neck Filter
180 MAINTENANCE AND LUBRICATION
MAINTENANCE INTRODUCTION
Preventive maintenance is vital to the life of your new vehicle. This section of
the Operator’s Handbook covers items of importance concerning the proper
care of MACK vehicles. A well-run maintenance and lubrication program is
the best way to ensure a long life of productive operation.
The operator plays an important role in the proper care of this equipment. By
performing daily checks and observing the equipment while in operation, minor
defects can be caught and corrected before they become major problems.
Make sure any problems are corrected before putting the equipment into
operation.
If you have any questions concerning the proper care, maintenance and
lubrication of your vehicle, or if you need help in developing a preventive
maintenance program, contact the service manager at the local MACK Sales,
Parts and Service Center.
Note: This handbook contains basic maintenance information. For complete

maintenance and lubrication procedures, refer to the Maintenance and Lubrication
Manual (21394653).
MAINTENANCE AND LUBRICATION 181
TURBOCHARGER
The engine turbocharger operates at very high speed, temperatures and
pressure. Turbo bearing lubrication is critical, particularly for a newly installed
turbo or one which has not been operated for a period of time and all oil has
drained from the bearing and shaft surfaces. To avoid turbocharger bearing
failure, the following instructions are recommended:
• Start the engine at least every 30 days to ensure turbo bearing lubrication.
Operate engine at low idle for at least three minutes before increasing RPM
or driving the vehicle.
• If the engine has not been run for more than 30 days, turbo pre-lube
procedure is necessary:
1. Remove turbo air intake duct and oil line connection at turbo.
2. Fill oil inlet fitting to overflow with clean engine oil.
3. Using fingers at compressor wheel, carefully spin and wiggle the turbo
shaft to distribute the oil over all bearing surfaces.
4. Reconnect air intake duct and again fill turbo oil port to overflow, connect oil
line and start engine.
5. Operate engine at low idle for at least three minutes before increasing
RPM or driving the vehicle.
CLEANING YOUR VEHICLE

The best protection against environmental influences that can hurt your
vehicle’s finish is frequent washing and waxing. How often this is required
depends on how much the vehicle is used, where it is parked and weather
conditions. Frequent washing is required to remove oils, dirt and grime that
can stain and oxidize the painted and polished surfaces of your new truck.
Exterior Washing
Recommendations for the first 30 days.
• Only wash the vehicle by hand with cool water, a mild car wash solution and
a soft cloth or sponge. Do not use a commercial truck wash.
• Wash the vehicle in the shade, never in direct sunlight.
• Do not dry wipe the finish; always use clean water. Dry wiping could scratch
the finish.
• Do not park near factories with heavy smoke fallout for extended periods
of time.
• Bird droppings have high acid content and can damage freshly painted
surfaces. They should be cleaned off as soon as possible.
• Do not spill gasoline, diesel fuel, oil, antifreeze, transmission fluid or any
solvents of the like on the new finish. If you do. IMMEDIATELY rinse off with
water. DO NOT WIPE.
• Do not scrape ice or snow from surface. Brush off the loose material with a
soft snow brush.
Recommendations for the first 90 days.
• Do not wax or polish the vehicle; this will allow the finish to dry and harden
completely. (Do not use waxes or polishes that contain silicone.)
Note: Do not wash the vehicle in direct sunlight.
DANGER
Test the service brakes after washing the vehicle. Moisture and/or ice on the
brakes can affect braking efficiency.
Note: When washing the vehicle in cold/freezing weather, avoid direct water spray
into the door lock cylinders, as the water may freeze in the lock mechanisms.
CAUTION
Proper care of the paint finish is an important part of the durability. Chemicals
used to wash the paint should be of neutral pH with a range of between 6 and 8.
Detergents containing butyl cellosolve or potassium hydroxide should not be used.
Note: Vehicles should be washed only in special wash bays to protect the environment
from cleaning agent contamination.
DANGER
Vehicle cleaning products must be handled carefully, as these products may be
poisonous. Keep all cleaning products out of the reach of children.
WARNING
Do not clean the underside of the fenders, cab, chassis, etc., without protecting
the hands and arms, as injuries may result when scraping against sharp edges.
CAUTION
For chassis used in concrete operations, do not use muriatic acid or similar types
of products to clean concrete from the cab or frame surfaces. Use of these types of
products will damage the paint finish and void the vehicle warranty. Mack Trucks,
Inc. has approved EL-ReadyMix Truck Wash & Wax for removing concrete from
the vehicle surfaces. This product is available on a direct ship basis from EMS®.
For additional information, contact EMS® at 800-510-8812, or on their web site
at www.enviromfg.com.
Note: Unprotected aluminum surfaces will form an oxide layer if not maintained.
This is especially important during cold season when roads are salted or in coastal
areas where the salt level in the air is high. Clean with steam or high pressure water.
Use a mild detergent if the dirt is heavy. Rinse well. Clean aluminum surfaces
with warm water. If the surface has heavy dirt or tar spots, use a tar remover. To
prevent spotting, wipe aluminum surfaces dry after washing. The use of an aluminum
protective Carnuba-based wax is recommended after washing for longer term
protection from road salts and spotting.
Cab and Hood

• Soften the dirt on your cab with plenty of water and rinse.
• Clean truck with a soft sponge/brush starting at the roof and working
downward using slight pressure.
• Use mild detergent. Never use strong soaps or chemical detergents. Any
commercially available cleaner designed specifically for automotive finishes
may be used for cleaning the cab and hood surfaces. The 3M company and
Mequiar’s® have a complete line of automotive cleaning products available
that are approved for use on MACK vehicles.
• Rinse the sponge or brush often to keep it clean.
• If possible, clean wheels and dirtier areas with a separate sponge/brush.
This will help avoid scratching body paint with grit from other areas.
• Rinse truck thoroughly with water and wipe dry with a soft clean chamois or
all cotton towels to avoid surface scratches and water spotting.
CAUTION
Do not clean the underside of the fenders, cab, chassis, etc. without protecting your
hands and arms. You may injure yourself on sharp-edged parts.
Chassis
• Wash away excess dirt and grime with water from a hose.
• Use a mild detergent/soap and a soft brush to remove road grime and salts
that can collect on the frame.
• Rinse thoroughly with a hose.
Note: Cleaning of your chassis on a regular basis will help deter accelerated corrosion
and rust on the frame and components. Chemicals used for ice and snow removal and
dust control can collect on the frame. If these are not removed in a timely manner,
accelerated corrosion can occur on fuel lines, frame, and other components even
though they have corrosion protection.
Cab Interior
• For cleaning vinyl upholstery and lining: wipe with a soft cloth, using a good
commercial upholstery cleaner. Do not use acetone, lacquer thinner, etc.
• For cleaning fabric upholstery: use an upholstery shampoo specially
designed for this purpose. Follow the directions on the manufacturers label.
Waxing
• Always use waxes and polishes that are non-abrasive. Do not use waxes or
polishes that contain silicone.
• When water does not form small drops and roll off clean paint, apply a coat
of good hard wax.
• Even if a liquid wax solution is used on a regular basis, it is advisable to
protect the finish with a hard wax at least twice a year.
• Your truck may have a basecoat plus clearcoat. Use a basecoat/clearcoat
wax on your paint finish.
Polishing
Polish your truck only if the paint has lost its shine and the gloss cannot be
brought back with wax. It is recommended to have a professional polish your
truck to avoid swirl marks or damage to the painted surface. Mequiar’s® has a
complete line of waxes, polishes and other cleaning and care products that
are approved for use on MACK cabs, hoods and sleeper surfaces.
Winter Warnings
• If you rinse your vehicle with a hose, avoid direct water into lock cylinders.
You may experience freezing of the lock mechanism.
• Test brakes after each vehicle wash. Moisture and ice on brakes can affect
braking efficiency.
A well kept vehicle can look like new after many years of service. Proper
care and maintenance can help you keep your vehicle’s beauty and value.
You can get an assortment of Mack Trucks approved cleaning products from
your local Mack dealer.
TOWING
Tow pins, hooks, eyes, etc., are located in or behind the front bumper. These
devices meet the recommendations for towing set forth by the Technology and
Maintenance Council (TMC) of the American Trucking Association and can be
used for towing a disabled vehicle from the immediate location.
If it is necessary to remove the tow pin, remove the retainer clip first. Once the
retainer clip is pulled, the tow pin can be lifted out of the bumper hole.
CAUTION
Do NOT lift and tow any vehicle by tow pins, hooks, eyes, etc. If the vehicle is mired
in heavy mud, snow, etc., use a suitable sling-type towing arrangement.
Note: Tow pins, hooks, eyes, etc., are NOT intended for use as long-term towing
devices.
CAUTION
Failure to disconnect the driveshaft, remove the drive axle shaft(s) or lift the drive
wheels off the ground before towing or pushing the vehicle, can cause serious
transmission damage.
DANGER
If the drive shaft has been removed for towing, DO NOT reuse bearing retainer
bolts or stamped strap bolts, or stamped straps. Reuse of bearing retainer bolts
or stamped strap bolts, or stamped straps can cause driveline failure, which can
result in separation of the driveline from the vehicle. A separated driveline can
result in property damage, serious personal injury or death.
C0029644
ENGINE OIL LEVEL CHECK

As the operator of this vehicle, it is important for you to perform the daily
inspections necessary to keep your truck in good shape. Maintaining the
proper oil level in your engine crankcase cannot be overemphasized.
Before checking the oil, remember these important points:
• Measurement of the oil level must be taken on level ground.
• The best time to check oil level is while the engine is COLD (prior to starting
at the beginning of the work day, or after the vehicle has sat approximately
2 hours). At normal operating temperature (engine oil temperature above
79.4°C [175°F]), oil level can be checked 15 minutes after shut down.
CAUTION
Failure to wait a sufficient amount of time (2 hours if engine oil temperature is
below 79.4°C [175°F]) or 15 minutes if oil temperature is above 79.4°C [175°F])
will result in an inaccurate dipstick reading.
• The level must be close to the FULL line (at least between the ADD and
FULL lines) on the dipstick, but must NOT exceed the FULL line (refer to
illustration below).
C0029422
Power Steering Reservoir

The Power Steering system uses only DEXRON® type automatic transmission
fluid.
C0029645
Power Steering Reservoir
1. Power Steering Reservoir
For additional information about power steering, refer to the Maintenance

and Lubrication Manual (21394653).
FUEL TANK
Your vehicle may be equipped with an isolated fuel tank. If so equipped, the
following label will be affixed to the fuel tank decal.
C0029424
Fuel Tank Cap

Use MACK approved non-vented cap only or tank damage and/or poor engine
performance may result. DO NOT fill to more than 95% of liquid capacity.
FUELING
DANGER
DO NOT carry extra fuel containers in the cab. Fuel containers, full or empty,
may leak, explode or give added fuel to a fire. Failure to follow this precaution
may lead to serious personal injury or death.
DANGER
DO NOT smoke while fueling the vehicle. The glow from the cigar/cigarette can
ignite the diesel fuel, causing an explosion resulting in serious personal injury
or death.
DANGER
Do not remove the fuel tank cap near an open flame. Diesel fuel vapors are
combustible and can cause an explosion or fire, resulting in severe personal
injury or death.
CAUTION
Diesel-powered engines for heavy-duty trucks built on or after January 1, 2010 are
designed to operate only with Ultra Low Sulfur Diesel (ULSD) fuel. Improper
fuel use will reduce the efficiency and durability of engines, permanently damage
advanced emissions control systems, reduce fuel economy and possibly prevent the
vehicles from running at all. Manufacturer warranties will be voided by improper
fuel use. Additionally, burning Low Sulfur Diesel fuel (instead of ULSD fuel) in
2007 and later model year diesel-powered cars, trucks and buses is illegal and
punishable with civil penalties.
CAUTION
Ultra Low Sulfur Diesel (ULSD) fuel with a maximum sulfur content of 15 ppm
must be used in order to meet Euro4 engine emission requirements.
Using otherwise approved diesel fuels with a maximum sulfur content greater than
500 ppm may shorten engine life and void the engine warranty.
Air is always present inside the fuel tanks, entering mainly through the tank
ventilation. With the air being heated and cooled, condensation is formed and
water is mixed in the fuel. To avoid condensation when the vehicle is parked
for longer periods, fill the tanks up to 95% of capacity. Do not fill more than
that, as the fuel needs to have room for expansion during the heat of the day.
BioDiesel
Soy Methyl Ester (SME or SOME) BioDiesel fuel in blends up to a B5
concentration (5% blend) is approved by Mack Trucks, Inc.
Note: Although higher concentrations are available, concentrations up to B5

(maximum) are the only blends currently approved by Mack Trucks, Inc.
Note: MACK Engines are certified to comply with U.S. EPA and California Air
Resources Board (CARB) emissions standards based on the use of reference test
fuels commonly available in the United States and specified in this manual. Use of
alternative fuels, including BioDiesel, may affect engine emissions. Mack Trucks,
Inc. does not warrant, and is not responsible for ensuring that the engines will comply
with U.S. EPA and CARB emissions standards.
B5 Approval For MACK US 2010 Certified Products

Mack engines are certified to comply with U.S. EPA and California emissions
standards based upon the use of test fuels with specifications established by these
regulatory agencies. Alternative fuels, including biodiesel, that are not substantially
similar to the required test fuels may adversely affect engine emissions compliance
and may impact the performance of certain emissions aftertreatment components. As
a result, Mack does not warrant the engine will conform to applicable Federal or
California emissions limits when operated on, or having operated on, biodiesel or
other alternative fuels that are not substantially similar to specified test fuels used for
certification.
The use of biodiesel up to a maximum of 20% (B20) in and of itself, will not affect
the manufacturers mechanical warranty as to engine or emissions system related
components except as limited below with respect to aftertreatment components,
provided the bio fuel used in the blend conforms to ASTM D6751, and B1 to B5
blends conform to ASTM D975, and B6 to B20 blends conform to ASTM D7467.
Failures of certain emissions aftertreatment components, specifically SCR, DPF and
NOx sensors will not be warranted if the failure can be attributed to operation on
biodiesel blends from 6 to 20% (B6 to B20) even if the biofuel used in the blend B6 to
B20 conforms to ASTM D7467 or any related standard.
COOLING SYSTEM
The cooling system is a pressurized system. The coolant is circulated by a
centrifugal pump. It is a typical system in most respects, but there are a few
things to keep in mind when checking or working on the cooling system.
Note: There is an auxiliary radiator located behind the cab that includes electrically
operated fans. The fans may begin to run at any time without warning. Keep clear of
fans.
WARNING
Keep clear of fan when engine is running. Fan may start to rotate at high
speed without warning.
WARNING
Avoid injury when checking coolant in a hot engine. Wait for the engine to
cool prior to checking the level whenever possible.
Coolant Level Check
WARNING
Turn the cooling system pressure cap counterclockwise to the first stop but do
NOT depress. After the pressure has completely dissipated, press the cap
downward and continue turning to remove.
Your MACK model chassis has a pressurized surge tank located on the
left-hand side of the chassis, mounted on the air cleaner assembly support
bracket. Coolant should be visible in the sight glass (see arrow in illustration)
located on the side of the tank.
W2056638
Draining the Cooling System

Whenever repairs are to be made which would require disconnection of
coolant hoses, etc., the cooling system should be drained. Carefully remove
the filler cap and remove all pipe plugs.
Refilling the Cooling System

Close all drain cocks and fill with the proper coolant mixture. Run engine
with the pressure cap removed until operating temperature is reached and
the thermostat opens. Recheck level and add coolant if required. Run the
engine long enough to be sure the system is free of air and has the correct
amount of coolant.
Protecting the Cooling System
CAUTION
The concentration of ethylene glycol or propylene glycol in the cooling system must
be checked with a refractometer prior to traveling or operating in areas where
subfreezing temperatures may be encountered. When adding antifreeze to the
system, run the engine for 20 minutes before checking with a refractometer.
Note: Your chassis is currently supplied from the factory with engine coolant
protection to –23°C (–10°F). Optional coolant protection to –40°C (–40°F) is also
available.
Ethylene glycol or propylene glycol-based antifreezes are both approved for

all MACK engines. All ethylene glycol and propylene glycol coolants must
be low-silicate antifreezes which meet ASTM4985 test (GM6038M SPEC)
criteria. These antifreezes are sometimes referred to as heavy-duty diesel
coolants. Passenger car coolants do NOT meet this specification.
Be sure to maintain the required level of antifreeze protection for anticipated
winter temperatures in your area of operation. A 40% to 60% concentration of
antifreeze is required for MP engines, regardless of application, geographic
location or ambient air temperature.
CAUTION
Do NOT exceed a 60% concentration of antifreeze to water. A higher percentage of
antifreeze will not increase protection. Concentrations over 60% adversely affect
freeze protection and heat transfer rates.
Note: Propylene glycol should be checked with a refractometer.
Note: ALWAYS mix the water/antifreeze solution before pouring it into the cooling
system.
Note: The piping arrangement may cause capacity variation depending on the type
of cooling system and optional external cooling devices which may be attached.
Therefore, it is difficult to tell exactly how much coolant it will take to fill any one
particular system.
CAUTION
Do NOT use coolant solutions which contain anti-leak additives in trucks equipped
with coolant filters or conditioners.
CAUTION
Do NOT use soluble oil-type coolants in any MACK cooling system.
Cooling System Maintenance

The cooling system must be maintained by performing regularly scheduled
maintenance as outlined in the Maintenance and Lubrication Manual
(21394653). Cold weather operations, however, place added demands on the
cooling system. Prevent potential cold weather problems by performing a
quick check of the cooling system as outlined below:
• Make a general check for cooling system leaks.
• Inspect hoses and clamps for leaks and condition. Tighten hose clamps to
specifications (as required).
• Check coolant level. Add fresh coolant (in specified concentration) as
necessary.
• Check and record degree of antifreeze concentration. Add antifreeze as
necessary to obtain required protection level.
For additional information concerning the cooling system, refer to the
Maintenance and Lubrication Manual (21394653).
Accessory Drive Belt Routing

The following diagram shows the accessory drive belt and main belt routing
with and without air conditioning. This diagram is located in a clear area on the
outside of the left frame between the radiator and center line of the front axle.
C0029647
Accessory and Main Drive Belt Routing
1. Accessory and Main Drive Belt Routing MP7 Engine

HEADLIGHTS
Bulb Replacement
Note: This vehicle uses a sealed beam type headlamp bulb which is not replaceable
without special tools. This vehicle should be taken to a qualified Mack Trucks dealer
for replacement.
WHEELS
Wheel Inspection
Look at the wheels and cap nuts. Inspect them for evidence of cap nut
looseness. Rust streaks from the cap nut ball seat are an indication of
looseness. Refer to the Maintenance and Lubrication Manual (21394653) for
complete procedures concerning wheel inspection and wheel nut tightening.
C0029431
Look for cracks around the hand hole, stud hole and wheel. Look for broken
studs, wheel damage or improperly seated lock rings.
C0029432
Tires
DANGER
Tires used on multipiece rims must be assembled and inflated only by experienced,
qualified personnel. Tires must be inflated in a safety cage whenever possible. If,
however, a safety cage is not available, use a portable lock-ring guard. The tire
must be deflated prior to removal of the tire-and-rim assembly from the vehicle.
Remove the valve core to ensure complete deflation.
DANGER
NEVER position your body in front of the rim during inflation.
CAUTION
NEVER use water-based sealants, puncture proofing, or liquid balance materials
containing water in All-Steel Radial Ply truck tires.
Inflation Pressure
To ensure maximum mileage and overall performance from your tires, it is
essential that they operate at the correct inflation pressure for the load carried.
Inflation pressure should be checked daily while the tires are cold. Always use
an accurate tire pressure gauge. NEVER bleed air from a hot tire, as it will
then be underinflated. Refer to the specific tire manufacturers data books, or
to the vehicle certification label for a complete listing of tire inflation pressures.
For additional information concerning tire care, refer to the Maintenance and
Lubrication Manual (21394653).
WARNING
UNDER NO CIRCUMSTANCES should you drive on underinflated or
overloaded tires. A tire in this condition builds up excessive heat which can
result in sudden tire destruction, property damage and personal injury.
CAUTION
Never bleed air from your tires in an attempt to gain traction for a vehicle stuck
in snow, ice or mud. This practice provides no additional traction and typically
results in underinflated tires. Never bleed air from a hot tire since that tire will
then be underinflated.
To adjust for pressure fluctuations induced by temperature changes associated

with winter weather, it is recommended that tire inflation pressure be checked
daily when the tires are cold (i.e., before the vehicle is driven). Always use an
accurate tire pressure gauge.
Inspection
Inspect your tires daily. Look for bulges, cracks, cuts, penetrations and/or
oil contamination. If any such damage is found, the tire must be thoroughly
inspected by a qualified tire inspector and repaired or discarded immediately,
at his discretion. Also, check for uneven wear. If found, a thorough inspection
of front end parts and alignment should be made by a qualified mechanic.
Refer to the Maintenance and Lubrication Manual (21394653) for more
information.
Tire Manufacturers Data Book

Specific and more detailed information can be obtained by referring to the
technical data books provided by each tire manufacturer.
Subjects of interest are:
• High-speed or low-speed operation
• Repair, retreading and regrooving
• Use of tire chains
• Mixing radial and bias tires on the same vehicle
• Use of dynamometers
• Tire mounting/dismounting
CAUTION
For important tire information (i.e., high speed limits, inflation pressures, etc.),
consult the product information available through the specific tire manufacturer.
Oil Contamination of Tires

Lubricating oils, fuel oil, gasoline and other petroleum derivatives, if allowed
to contact tires, will soften the rubber and destroy the tire. Preventive
maintenance is necessary to ensure that oil leakage does not occur. The
following areas should be inspected on a regular basis:
• Axle end seals
• Engine seals
• Transmission seals
• Drive axle seals
• Oil filters
• Oil and hydraulic lines (if equipped)
• Refer to the Maintenance and Lubrication Manual (21394653), specific
tire manufacturers books, or to the vehicle certification label, for additional
information concerning tires and their care.
BATTERY
CAUTION
To avoid damage to sensitive electronic equipment, disconnect ALL battery cables
and harnesses to electronic control units before welding. Do NOT disconnect
batteries while engine is running.
Jump-Starting Engine
If you encounter a situation in which it is necessary to jump-start an engine,
use the following procedures.
WARNING
Batteries which are to be linked together must be of the same voltage (12 to
12, 24 to 24). Take care to observe proper polarity when connecting batteries.
Batteries produce explosive gases. Keep sparks, flames, cigarettes, etc., away
from batteries at all times. Protect your eyes by wearing safety goggles. Be
sure vehicles are NOT touching each other.
CAUTION
To avoid damaging any electronic controllers when jump-starting a V-MAC vehicle,
always turn the ignition switch OFF before connecting the batteries.
1. Connect the positive (+) cable to positive (+) post of discharged battery or
to the positive post of the remote jump-start connector (if equipped).
2. Connect the other end of the same cable to the positive (+) post of the
booster battery.
3. Connect the second cable, negative (-) side, to the other post of the booster
battery.
4. Make the final connection to the negative (-) battery terminal or the remote
jump-start connector (if equipped) of the stalled vehicle, and stand back.
5. Start the vehicle with the booster batteries and then start the stalled vehicle.
Shut down the vehicle with the booster batteries and remove the cables in the
reverse order of connection.
WARNING
Do NOT connect the final negative (-) connection to the frame of the stalled
vehicle. This would cause all current to flow through the master ground circuit
breaker resulting in overload.
ELECTRICAL
Circuit Breaker and Relay Panels

The electrical equipment cover for this vehicle is located under the dash on
the left-hand side of the cab. The label for this panel may be located under
the driver left side operating position, behind the access panel. You need to
remove the panel in order to view this label.
C0029648
The cover panels are fastened with screws. Most relays and fuses are
accessible from under the top cover. Since the function of some fuses or
relays may change for the vehicle operation, refer to the list of functions that is
attached beneath each panel.
C0029649
C0029650
C0029651
Note: For circuit breaker designations, refer to the Circuit Protection charts.
Fuses are standard equipment for all circuits except the headlamps and
windshield wipers. Circuit breakers are available as optional equipment.
CAUTION
For proper installation of electrical accessories, all wiring should meet SAE
requirements and be routed through the circuit protection panel with proper
amperage fuses or Type II circuit breakers. (Headlights and wipers will be on
Type I, cycling-type circuit breakers.)
Some vehicles may be equipped with daytime running lights. For the daytime
running lights to be operational, a DRL module must be installed in the
relay socket marked either DRL MOD or Running Lamps on the electrical
equipment panel. Do NOT install a standard relay into the daytime running
light relay socket (marked either DRL MOD or Running Lamps) or a short
circuit in the headlight high beam circuit will result.
The headlight circuits are protected by SAE Type I (automatic reset-cycling)
circuit breakers that automatically interrupt then restore the flow of current
through the circuit in the event of an overload. This cycling will continue until
the cause of the overload is repaired.
SAE Type II (automatic reset, non-cycling) circuit breakers (if equipped)
provide a complete circuit disconnect until the overload is corrected. The
power to the affected circuit breaker must be shut off before the circuit breaker
will reset itself.
The circuit protection panel also provides access to battery, ignition and
ground terminals for non-factory installed electronic equipment. (On V-MAC
chassis, there are two serial link terminals for easy local connection of a trip
recording device.)
Electrical Grease
To prevent corrosion of the lamp socket terminals, particularly with the
clearance and marker lamp, apply a coating of electrical sealing grease, such
as Lubriplate DS-ES or TEK-519, to the socket and terminal assemblies.
CAUTION
Do not use electrical grease on any V-MAC connectors.
Circuit Protection Charts

Cab Circuit Protection (V-MAC IV)
CB2 — 15 CB3 – 15 CB4 – 20A F5 – 10A
Headlamps Hi Park & Tail Lps. Turn Signals Tractor
Beam Flasher Emergency Stop
Lps.
F6 – 10A F7 – 10A F8 – 15A F9 – 15A
Dome Lps. Key Switch Air Sol. CB Posts
Courtesy Lps.
F10 – 5A F11 – 15A F12 – 15A F13 – 15A/20A
Diag. Conn. Battery Stud Battery Stud ABS Battery
F14 — 30A F15 – 15A F16 – 10A F17 – 10A
Aux. Fan Cool Beacon Lamps VECU EMS VECU Ctrl. Sw.
Power Input
F18 — 10A F19 — 5A F20 – 10A CB21 – 20A
DCL EMS Power Instrument LH Windshield
Moto Mirrors
Cluster Battery Wiper & Washer
CB22 — 20A CB23 – 10A F24 – 15A F25 – 30A
RH Windshield WS 2 Way Radio Opt. HVAC Cab Unit
Wiper & Washer Wiper/Washer
F26 — 15A F27 – 15A F29 – 10A F30 – 10A
Rear Flood Ignition Stud EMS Relay Munc. PTO
Opt. Ign.
F31 — 10A F32 – 15A F33 – 20A F34 – 30A
Trans. Ign. Body Builder Trailer Stop Lps. Reverse/Neutral
Battery 2 Power
F35 — 25A F36 – 15A F37 – 25A F38 – 30A
Clearance Lamps Horn Tail Lamp Engine Ctrl. Unit
Cab Circuit Protection (V-MAC IV)

F39 — 30A F40 – 25A F41 – 15A F42 – 10A
Trailer ABS Body Ignition Engine Acc. Back-Up Lamp
Power Stud
F43 — 15A F44 – 20A F45 – 30A F46 – 10A
Eng. Comp #2 Heat/Air Dryer Fuel Heater Power Outlet
F47 — 15A F49 – 10A F50 – 10A F51 – 10A
Spare EMS ABS Ignition Head Lamp Left Head Lamp Right
Low B
F52 — 15A F54 – 20A F55 – 20A F56 – 10A
Spare Brake DPF Battery Heated Mirror Telma
Wear
F57 — 15A F58 – 5A F60 – 15A F61 – 20A
HVAC Roof Unit L-R Relay Ctrl. Engine Comp #1 Body Battery
Stud
F62 — 30A F63 – 5A F64 – 10A F65
Aux. Fan Cool Instrument DPF Ignition Open
Package Cluster (EMS)
F66 — 15A F67 F68 – 15A F69
Spare Ign. Open Cigar Lighter Open
F71 — 10A F74 – 5A F75 – 25A F76 – 25A
Trans. Battery Radio Mem. Spare Spare
F77 — 5A
Spare
212 METRIC CONVERSIONS
METRIC CONVERSIONS
Note: Use all tools on the fasteners they were made to be used on. Use metric tools
on Sl metric units only. Never try to use metric tools on U.S. standard fasteners or
U.S. standard tools on Sl metric units.
CAUTION
Potential external/internal thread mismatch condition(s) may occur with certain
metric thread-inch thread fastener combinations, and with fastener combinations
involving incompatible metric fastener systems. A given thread mismatch condition
can result in thread stripping and/or assembly weakness leading to potential
service failure, thereby rendering a vehicle non-operational and/or unsafe for
operation. The specific external/internal thread combinations from which such
problems can result are identified and set forth in Maintenance and Lubrication
Manual (21394653).
METRIC CONVERSIONS 213
SI to U.S. Conversions
25.4 millimeters = 1 inch
1.61 kilometers = 1 mile
.473 liter = 1 pint (U.S. liquid)
.946 liter = 1 quart (U.S. liquid)
.01639 liter = 1 cubic inch
1.3558 Newton meters = 1 pound-foot
.746 kilowatt = 1 horsepower
6.895 kilopascals = 1 pound/square inch
(1.8 x degrees Celsius) + 32 = degrees Fahrenheit
.83267 Imperial gallon = 1 gallon (U.S. liquid)
U.S. to SI Conversions
.03937 inch = 1 millimeter
.6214 mile = 1 kilometer
2.1134 pints (U.S. liquid) = 1 liter
1.0567 quarts (U.S. liquid) = 1 liter
61.024 cubic inches = 1 liter
.7376 pound-foot = 1 Newton meter
1.34 horsepower = 1 kilowatt
.145 pound/square inch = 1 kilopascal
.556 x (degrees Fahrenheit -32) = degrees Celsius
1.2009 gallons (U.S. liquid) = 1 Imperial gallon

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Mack LEU Series

(LEU Series) (LEU Series)

21394654 © Mack Trucks, Inc. 2010 21394654

Mack Truck, Inc.

Order number: PV776-21394654

©2010 Mack Trucks, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced,

Note: Note indicates a procedure, practice,

About This Handbook

Vehicle Management and Control System

Engine Information Plate

Engine Identification Label - 49 State EPA Approved Engine

Engine Identification Label - 50 State EPA Approved Engine

Clean Idle Engines

Clean Idle Engine Label

Air Brake System

ENGINE GASEOUS EMISSION CONTROL

ENGINE GASEOUS EMISSION CONTROL SYSTEMS

Qualifications and Limitations:

Emissions Control System Warranty

1 Turbocharger Assembly • CAC Hoses

5 Engine and Vehicle Wire harness ( • Aftertreatment DPF Intake

16 Aftertreatment Diesel Particulate Filter

• Aftertreatment Outlet NOx • Aftertreatment DEF Tank Heater

• Ambient Air Temperature (AAT) • Aftertreatment DEF Tank

ENGINE GASEOUS EMISSIONS CONTROL

FEDERAL EMISSION REQUIREMENTS

3 Any person engaged in the business of

EMISSION CONTROL SYSTEMS WARRANTY —

OWNER’S WARRANTY RESPONSIBILITIES:

Qualifications and Limitations:

Not covered by the Emissions Control • Inconvenience, loss of use of the

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES

Emissions Control System Warranty

1 Turbocharger Assembly • Aftertreatment Doser

5 Engine and Vehicle Wire harness

• Aftertreatment DPF Fuel Control • Aftertreatment Selective Catalytic

• Intake Manifold Air Temperature • Aftertreatment DEF Heated Lines

ENGINE GASEOUS EMISSION CONTROL SYSTEMS

1. Repairs by MACK Dealers, 3. Repairs by Non-MACK Facilities

• Malfunctions caused by misuse, Warranty Activities

MACK Class 8 –Components Service Manual

Note: If your vehicle contains a number of non-MACK (vendor) components, the

MACK Class 8 – Custom Collated Service Manual

Call 1-800-866-1177 for MACK OneCall™

Questions and Complaints

• Vehicle Identification Number (VIN) — This 17-digit number is typically located

• Model and year of the vehicle

REPORTING SAFETY DEFECTS

EVENT DATA RECORDING DEVICES

Safety Certification Label

A chassis-cab is an incomplete vehicle with a completed occupant

Advisory Label Locations (On Vehicle)

Labels Found on Driver-Side Sun Visor

Labels Found on Cowl (Near Ashtray)

Labels Found on Instrument Panel

Eaton Controlled Traction Differential Label

Labels Found on Fuel Tank

Back Up Alarm (Optional)

SAFETY TIPS FOR COLD WEATHER OPERATION