dear mack® owner - big truck rental

Dear Mack® OwnerCongratulations on your new truck and thank you for your confidence! We hope youwill derive great satisfaction and benefit from your truck for many years to come.

This driver’s manual contains information tailored to your particular truck. It covers thetruck's equipment, care and maintenance, as well as tips for safe and fuel-efficientdriving. To help you get the most out of your truck, we recommend that you takeadvantage of our advice and tips.

If you have any questions or want to know more about your truck, contact yourauthorized Mack dealer.

©2015 Mack Trucks, Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in a retrievalsystem, or transmitted in any form by any means, electronic, mechanical,photocopying, recording or otherwise, without the prior written permission of MackTrucks.

Service and Assistance

Mack® OneCall™The OneCall™ customer support system is a toll-freenationwide hotline that operates 24 hours a day, seven days aweek, including holidays.

If you break down on the road, simply call 1-800-866-1177.There is a staff of trained, experienced technicians ready tohelp. They can help troubleshoot a problem, arrange roadsideassistance or towing to the nearest Mack dealership.

OneCall™ provides personalized service. Your personalrepresentative can resolve your situation quickly and to yoursatisfaction and handle any additional follow-up calls.

OneCall™ technicians can also help you plan ahead to keepyour operation running efficiently. They can schedule routinemaintenance and lubrication service or locate the nearestMack dealership.

Questions and ComplaintsYour satisfaction is our most important concern.

If questions or complaints arise, first discuss the matter withthe service manager at the Mack facility involved. If you are notsatisfied with the service managers response, contact thebranch manager, principal or general manager of thedistributorship. If assistance is required at a service dealer,contact the owner of the establishment.

If for any reason you need further assistance after dealing withthe personnel at a Mack subsidiary or distributor, contact theregional service manager. The regional service manager hasthe responsibility and authority to recommend action and (withthe aid of relevant district service personnel) make every effortto conduct a fair review of the situation.

AddressesThe address, telephone and fax numbers of the Mack Trucksregional offices are:

United StatesNortheast Region – 2402 Lehigh Parkway South, Allentown, PA18103TEL: (610) 351-8770,FAX: (610) 351-8737

Southeast Region – 2077 Convention Center Concourse,College Park, GA 30337TEL: (404) 766-5515,FAX: (404) 766-4710

Central Region – 900 South Frontage Rd., Suite 100,Woodridge, IL 60517,TEL: (630) 910-3330,FAX: (630) 910-3331

Southwest Region – 7 Village Circle, Suite 340, Dallas, TX76262TEL: (817) 541-3602

West Region – 1263 West Maya Way, Peroia, AZ 85383TEL: (949) 636-0473,FAX: (817) 541-3610

CanadaExecutive Office – Mack Canada, Inc., 2100 Derry Road West,Suite 410, Mississauga, ON L5N 0B3TEL: (289) 998-0070,FAX: (289) 998-0065

AustraliaExecutive Office -20 Westgate St., Wacol 4076, Mail: P.O. Box4047,Mt Ommaney, QLD 4074, Australia,TEL: 61-7-3718-3500,

FAX: 61-7-3718-3391

Additional AssistanceWhen contacting the regional service offices or CustomerService Department, provide the following information:

• Vehicle Identification Number (VIN) — This 17-digit number istypically located on the driver-side door latch post and behindthe front axle on the right, front frame rail.

• Model and year of the vehicle

• Date that the vehicle was purchased and put into service

• Date(s) and mileage of repair(s)

• Dealer that sold and/or serviced the vehicle

• Description of unresolved service complaint or inquiry

• Summary of action taken to date (by the dealer and theregional service office)

• Names of individuals (if known) contacted at the dealer andthe Mack Trucks regional service office

Reporting Safety DefectsUnited States

If you believe that your vehicle has a defect which could causea crash, injury or death, immediately contact the NationalHighway Traffic Safety Administration (NHTSA), in addition tonotifying Mack® Trucks.

If NHTSA receives similar complaints, it may open aninvestigation. If NHTSA finds that a safety defect exists in agroup of vehicles, it may order a recall and remedy campaign.However, NHTSA cannot become involved in individualproblems between you, your distributor, or Mack® Trucks.

To contact NHTSA, either call the U.S. Governments VehicleSafety 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 alsoobtain other information about motor vehicle safety from theVehicle Safety Hotline.

Canada

Canadian customers who wish to report a safety-related defectto Transport Canada — Defect Investigations and Recalls,telephone the toll free hotline at 1-800-333-0510, or contactTransport Canada by mail at Transport Canada, ASFAD, Placede Ville Tower C, 330 Sparks Street, Ottawa ON K1A 0N5. Foradditional road safety information, please visit the Road Safetywebsite at http://www.tc.gc.ca/roadsafety/menu.htm.

Mexico

Volvo Trucks de Mexico, S.A. de C.V. should be informedimmediately if you believe the vehicle has a defect that couldcause a vehicle accident, injury or death. Contact Volvo Trucksde 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 laReforma 600, 1er. Piso — 121, Col. Santa Fe Pena Blanca,C.P. 01210, Mexico, D.F. Within Mexico, call 01 (800) 90 94900.

TABLE OF CONTENTS

INTRODUCTION

Important Information......................... 2Identification Labels............................ 4General Safety Information................. 7Warranty Information........................ 13Warranty Certificates........................ 20

DRIVING TIPS

Driver Environment........................... 42Starting............................................. 44Driving in an Urban Area................... 46Driving on a Highway........................ 48Driving in Hilly Terrain....................... 50Driving on a Wintry Road.................. 52Driving in a Dusty and SmokyEnvironment...................................... 54Driving in the Rain............................. 56Parking.............................................. 58Service and Maintenance................. 60Driving on a Slippery Road............... 62

SAFETY

Seat Belts.......................................... 66

TABLE OF CONTENTS

LOCKS AND ALARM

Locks and Alarm............................... 70

DRIVING ENVIRONMENT

Overview of Instruments................... 74Climate Control System.................... 83Cab Tilt.............................................. 84Light Control Panel........................... 89Steering Column............................... 90Seats................................................. 91Miscellaneous Cab Equipment......... 93Mirror Systems.................................. 95

STARTING AND DRIVING

Power Supply.................................... 98Fuel Tank Cap................................... 99Fueling............................................ 100Use of Biodiesel.............................. 101Starting the Vehicle......................... 102Fuel Economy Driving..................... 107Axles............................................... 110Vehicle Speed Retarding Devices... 112Allison Transmission....................... 113Anti-Lock Braking System.............. 128

TABLE OF CONTENTS

INFOTAINMENT

Radio............................................... 132

MAINTENANCE, LUBRICATIONAND SERVICE

Pre-Trip Inspection and DailyMaintenance................................... 140Pre-Trip Inspection Quick List......... 141Service Charts................................ 146Engine ............................................ 153Engine Oil........................................ 158Engine Oil and Filter Intervals......... 161Oil Capacity Table and Viscosity Charts........................................................ 162Engine Storage............................... 163Electrical System............................ 164Turbocharger / Charge Air Cooler... 170Drive Belt Replacement Intervals.... 171Drive Belt Routing........................... 173Cooling System............................... 175Fuel System.................................... 179Tires, Wheels and Hub ................... 184Driveshaft Lubrication..................... 189Engine Air Filter............................... 190Air Suspensions.............................. 192Steering and Brakes Maintenance.. 193Chassis Maintenance...................... 197

Cab Maintenance............................ 198Lubrication...................................... 199Headlamp Bulb Replacement......... 204Wiper Blades................................... 205Vehicle Cleaning............................. 206Seat Belt Maintenance.................... 208Front Bumper / Plate Mounting...... 209Metric Conversions......................... 210

TABLE OF CONTENTS

EMERGENCY ACTION

Towing............................................. 214Jump-Starting Engine..................... 219

INTRODUCTION

INTRODUCTION

IMPORTANT INFORMATION

Read the Driver'sHandbookThe contents of this driver’s manual aredetermined by the equipment, thesystems and the functions that the truckhas. Due to the VIN specific nature ofthis manual the information should bestored in the truck to which it belongs.

Please read through the driver’s manualbefore you drive the truck for the firsttime. This is a good way to learn moreabout the functions and equipment thetruck has, and to be able to use themproperly.

The table of contents in the front of themanual gives you an overview of thechapter structure and contents. In thealphabetical index at the back you cansearch directly for specificcharacteristics or functions.

Premium Tech Tool™ (PTT)

Premium Tech Tool™ (PTT) is aWindows-based diagnostic applicationspecially designed to test, calibrate andprogram engine parameters. Thissoftware supports all Mack trucks.

You can find more information aboutpurchasing PTT and other hardware &software components atwww.premiumtechtool.com.

NOTESupport for Mack trucks may be limitedwith model years 1998 and older.

PTT Technical SupportFor Technical Support (help with usingthe software, problems encounteredwhile using the software, communicationissues, etc.), please call 877-978-6586.

Parts and Service SupportFor Parts and Service information needsplease visit our eMedia center on theweb at www.macktrucks.com.

Special TextsThe driver’s manual uses the followinglevels of observation and warning texts.

DANGERIndicates a potentially dangerous situationthat, unless avoided, will lead to death orserious personal injury.

WARNINGIndicates a potentially dangerous situationthat, unless avoided, may lead to fatalinjury, serious personal injury or damageto the product.

CAUTIONIndicates a potentially dangerous situationthat unless avoided may lead to minor ormoderate personal injury or damage to theproduct.

NOTEIndicates a situation, use or circumstancethat should be emphasized.

Menu TextWhen the text refers to any of the menusthe search path is shown in a table.

Driver Information DisplayMain menu 1

Submenu 2

Submenu 3

2 X _Publication_PC29

INTRODUCTION

IMPORTANT INFORMATION

GuardDog® ConnectNOTE

Do not run any electrical accessories orinverter during remote software updateoperation.

Your vehicle is equipped with one ormore recording devices (TelematicsDevice), associated with Mack'sConnected Vehicle Services and(Telematics Services).

These services, which are described ingreater detail at www.macktrucks.com,allow you to manage vehiclemaintenance and repair in a cost-effective manner by providing:

• proactive, diagnostic repair planningassistance with detailed analysis ofdiagnostic trouble codes

• streamlined service procedures withparts-on-hand confirmation before atruck arrives for service

• live dealer and customercommunication

• remote updates to vehicle softwareand configuration

The service eliminates or reducesdiagnostics time, enhances repairefficiency, expedites decision process,improves communications, andmaximizes uptime.

To access the Telematics Services, youmust enter into a TelematicsSubscription Agreement. This can bedone at the time of the vehicle deliveryor through the website.

The Telematics Device collects, storesand/or transmits information about yourvehicle. Such information may includedirection and rate of speed, fuelconsumption, engine performance,gearing, rpm, altitude, geo-location(including a history of where the vehicletravels), safety information related to theuse and operation of the vehicle, vehicleperformance, diagnostic data,configuration information, and errorcodes.

The Telematics Device has the capacityto store historical data about the useand performance of your vehicle, and toremotely update vehicle software andconfiguration to improve performance.The Telematics Device has the ability totransmit information to a centralcommunications system. Theinformation contained in your TelematicsDevice may be periodically transmittedto or accessed by Mack and othersauthorized by Mack, along with yourvehicle's VIN number or other identifyinginformation.

Mack does not collect any driverinformation. Mack retains and uses thisinformation to understand the operation

use of your vehicle, to remotely tuneyour vehicle and to help facilitatemaintenance and vehicle improvements.To the extent allowed by law, Mackreserves the right to access, use, andcontrol this information.

Declining to enter into a TelematicsSubscription Agreement with Mack orcanceling a Telematics SubscriptionAgreement will not end the transmissionof data from your Telematics Device orthe collection of information by Mack.Mack may access Telematics Data, tothe extent it is available, and use it inconnection with providing services andvehicle improvements to you and yourvehicle.

Mack will regularly purge from itssystems all data collected from yourTelematics Device, at time intervalsdetermined by Mack at its solediscretion.


INTRODUCTION

IDENTIFICATION LABELS

Breaking In a NewVehicleTo ensure many years of reliable,trouble-free operation, the followingbreak-in procedures are recommended.

Refer to the preventive maintenanceschedules for recommended changeintervals for the following items:

• Gear oils (transmission, rear axlecarrier[s], front drive axle carrier,transfer case, flywheel PTO)

• Engine oil

• Oil filters

• Fuel filters

• Coolant conditioner

During the First 5000 Kilometers(3000 Miles)• After the first 200 km (125 miles),

retorque the wheel nuts using anaccurately calibrated torque wrench.Recheck this torque again after 800km (500 miles).

• Check oil and coolant levelsfrequently.

• Check brake and clutch adjustmentsper recommended maintenanceschedule, and adjust as needed.

• Observe the instruments often, andshut down the engine at the first signof any abnormal readings.

• Report all leaks, loose fasteners,unusual noises, etc., to the servicerepresentative at the nearest Mackdealership so they can be checkedand corrected.

Although this quality-built vehicle hasbeen inspected, lubricated and adjustedat the Mack Trucks Assembly Plant,occasional air, oil or coolant leaksdevelop. Quick action to correct theseminor items prevents major repairs later.Take the vehicle to the nearest Mackservice center if an abnormal conditionbecomes evident.

Initial Valve Adjustment IntervalsRefer to the Maintenance andLubrication section for detailedinformation concerning the Initial ValveAdjustment Interval.

Temporary Loss of PowerOutputWhen driving in difficult drivingconditions e.g. high temperatures, highengine speeds and high loads, thetemperature in the exhaust system maybecome abnormally high. This couldactivate the engine's protection system.The engine's power output is reducedtemporarily. The power output is

restored to normal performance whenthe temperature has dropped.

Contact an authorized Mack dealershipif the engine power output is notrestored.


INTRODUCTION


Engine IdentificationOn the Mack MP engines, the engineserial number is stamped on the left sideof the engine block, below the inletmanifold.

1 Engine Identification Label

Engine Information PlateIn compliance with Federal andCalifornia emission requirements, anengine information label is affixed to allMack diesel engines. This label, which islocated on the cylinder head cover atthe front of the engine, gives basicengine identification information (enginemodel, serial number, etc.), advertisedhorsepower at rated speed, emissionsregulations to which the engineconforms and inlet and exhaust valvelash settings. Examples of the 49 stateEPA approved, and 50 state EPA andCalifornia approved engine identificationlabels are given below.

Clean Idle EnginesThe California Air Resources Board(CARB) requires that 2008 and latermodel year vehicles be equipped withengines having tamper-resistantsoftware which limits the time at whichthe engine can idle at speeds above lowidle (550–700 rpm). At speeds above lowidle, and without a PTO engaged, idletime will be limited to five minutes. Theengine then reverts to low idle. Vehiclesequipped with a Clean Idle engine havea label affixed to the vehicle.


INTRODUCTION


Transmission Identification

Allison Identification LabelThe Allison RDS and HS transmissionidentification plate is located on the rearright side of the main case, near thelower end.

1 Allison Identification Label

Rear Axle Identification LabelThe Meritor rear axle identification tag islocated on the left or right rear of therear axle housing, next to the carrier.

1 Rear Axle Identification Label

Carrier Identification LabelThe Meritor carrier assembly serialnumber is located on the left side of theforward carrier, and the top of the rearcarrier.

1 Carrier Identification Label


INTRODUCTION

GENERAL SAFETY INFORMATION

Safety Statement andLabelsMack Trucks cannot anticipate everypossible occurrence which may involvea potential hazard. An accident can beavoided by recognizing potentiallyhazardous situations before a dangeroussituation occurs. Correctly performedservice procedures are critical fortechnician safety and safe, reliableoperation of the vehicle.

DANGERDo not operate the engine in an enclosedarea. All internal combustion engines giveoff various fumes and gases whilerunning. Inhalation of exhaust fumes cancause death.

DANGERDo not sit in a parked vehicle for anyextended amount of time with the enginerunning if there are leaks in the exhaustsystem. Exhaust fumes could leak into thecab area and death can result. On aregular basis inspect the exhaust systemfor leaks and repair any leakage.

DANGERDriver attitude is the most important partof any effective vehicle safety system.Mack Trucks encourage all drivers andpassengers to use their seat belts, drivedefensively, remain alert and respect thespeed limits. Many accidents can also beavoided through regular vehiclemaintenance.

DANGEREngine-driven components such as PowerTake-Off (PTO) units, fans and fan belts,driveshafts and other related rotatingassemblies, can be very dangerous. Donot service engine-driven componentsunless the engine is shut down. Alwayskeep body parts and loose clothing out ofrange of these powerful components toprevent serious personal injury. Be awareof PTO engagement or nonengagementstatus. Always disengage the PTO whennot in use.

WARNINGCertain everyday procedures such aswashing the vehicle and cleaning thewindshield can also be hazardousbecause of the vehicles height. MackTrucks does NOT recommend climbing upon the vehicle to perform thoseoperations. Instead, stand on the groundand use brushes and squeegees mountedon an extension pole. When better accessis necessary (for instance, when washingthe cab roof), use sturdy ladders held inplace by someone on the ground.

WARNINGSecure loose objects. Loose objects in thecab or sleeper can be dangerous in asudden stop or on bad roads. Secure anyappliance added to the vehicle, such as arefrigerator or a radio.

WARNINGKeep clear of fan when engine is running.Fan may start to rotate at high speedwithout warning.


INTRODUCTION


Labels

Safety Certification LabelNational Highway Traffic SafetyAdministration (NHTSA and TransportCanada) regulations require affixing acertification label to all vehicles.

The regulations also require that thecertification label be affixed to either thehinge pillar, door latch post or the dooredge that meets the door latch post nextto the driver seat. If none of theselocations are practical, it may beattached to the left side of theinstrument panel or to an inward facingsurface of the driver-side door.

Your vehicle has a safety certificationlabel affixed in one of the approvedlocations listed above. This label may beeither an Incomplete Vehicle orCompleted Vehicle label. Both labels aredescribed below.

Incomplete VehiclesA chassis-cab is an incomplete vehiclewith a completed occupantcompartment that requires the additionof cargo-carrying, work-performing orload-bearing components to perform itsintended functions.

When the vehicle is completed thechassis-cab manufacturer must affix afinal stage manufacturer certification

label to the complete vehicle in one ofthe approved locations listed above.

This label indicates that the chassis cabwas completed and complies with theapplicable Motor Vehicle SafetyStandards (MVSS). This label is requiredto contain the same information asshown below for a completed vehicle.

Completed VehiclesIn addition to the label supplied byMACK as the chassis-cab manufacturer,a Completed Vehicle certification label,supplied by the body manufacturer, isaffixed in the same general location. Thislabel provides information pertaining toGross Vehicle Weight Rating (GVWR),Gross Axle Weight Rating (GAWR), tireand rim information, etc.

On completed vehicles, this labelcontains the date of manufacture, VIN,GVWR, GAWR, and tire and rim data. Itis found in one of the approved locationslisted above.

Advisory LabelsThroughout this book you will findparagraphs labeled Danger, Warning,Caution, Note and Service Hint. Danger,Caution and Warning labels are alsofound in various locations on the vehicleto alert drivers, operators and servicetechnicians to situations which cancause personal injury or equipmentdamage. The labels shown areapplicable to the truck model chassis atthe time of publication and arerepresentative of what can be typicallyfound on your vehicle. Your vehicle maynot contain all of the labels illustrated inthis handbook. These labels are for yourbenefit. Please look through this sectionand note the labels, their locations andwhat they explain. Be sure to replaceany label that is damaged.


INTRODUCTION


Advisory Labels On Chassis

1 Entering / Exiting Label

2 Frame Crack Label

3 Suspension Torque Label

4 Personal Injury Label


6 Fan Warning Label




INTRODUCTION



2 Body Installer Label

3 Cab Tilt Label


5 Transmission Fluid Label


INTRODUCTION


1 Engine Starting Warning Label

2 Transmission/Shifting Pattern Label

3 Exhaust Temperature Label

4 Exaust Aftertreatment (EATS) Label


INTRODUCTION



6 Speed Retricted Tire Label

1 Back Up Alarm Label (If Equipped)

1 Airbrake System Label


INTRODUCTION

WARRANTY INFORMATION

Warranty InformationThis chassis is equipped with anexhaust aftertreatment system (DieselParticulate Filter). Use of Ultra LowSulfur Diesel (ULSD) fuel and EO-OPremium Plus (or VDS-4) specificationhigh performance diesel engine oil isrequired in this vehicle.

NOTENote: Use of improper or unapproved fuelor engine oil will void the engine andaftertreatment system warranty.

Air Brake SystemThe Mack Trucks Standard VehicleWarranty applies to the air brakesystem, as set forth in the Warranty, butonly if the air brake system has not beensubjected to unauthorized additions,deletions or modifications. If any suchunauthorized additions, deletions ormodifications are performed, MackTrucks disclaims any and all liability forany loss or damage arising out of amalfunction of the air brake system.

The air brake system was designed andbuilt to conform to all applicable federalmotor vehicle safety standards in effectat the time of manufacture.

Tractor air systems are designed foroperation as a tractor only, and truck airsystems are designed to be operated as

a truck only. If a tractor is going to beconverted for operation as a truck, theair brake system must be reconfiguredto that of a truck. Conversely, if a truckis going to be converted for operation asa tractor, the air brake system must bereconfigured to that of a tractor. Consultyour local Mack distributor for additionalinformation.

If any unauthorized additions, deletionsor modifications are made to any portionof the air brake system which is requiredby Federal Motor Vehicle SafetyStandards, Mack Trucks makes norepresentation as to conformity with theStandards.

For complete warranty information, referto the Pedigreed Protection Planprovided with each vehicle.

Federal and CanadianEmission Control SystemWarranty StatementThis section covers the requirement ofthe United States Clean Air Act whichstates: “The manufacturer shall furnishwith each new motor vehicle or motorvehicle engine such written instructionsfor the maintenance and use of thevehicle or engine by the ultimatepurchaser as may be reasonable andnecessary to assure the properfunctioning of emission control devices

and systems.” This section also coversthe requirements of the emissionsregulations promulgated under theCanadian Environmental Protection Act,1999.

Manufacturer WarrantyCoverageMack Trucks warrants the EmissionControl Systems on each new Mackdiesel engine in a new Mack Truck tocomply with all United States Federaland Canadian emissions regulationsapplicable at the time of manufacture ofthe engine, and to be free from defectsin material and workmanship undernormal use and service up to 60months, or 160934 km (100,000 miles),whichever occurs first, provided that allmaintenance requirements are followedas described in this manual.All warrantyperiods are calculated from the date-in-service of the new vehicle. The repair orreplacement of defective parts will bemade without charge for the cost ofparts and if repairs are made at anauthorized Mack dealership, there willbe no charge for labor.

Mack's obligation under this warranty islimited to the repair or replacement, atMack’s option, of any part(s) of theEmission Control Systems of suchengine and/or vehicle found to bedefective upon examination by MackTrucks and provided that such part(s)


INTRODUCTION


were returned to Mack Trucks or itsnearest authorized Dealer within areasonable period of time.

NOTENote: For emission control systemsinformation on engines other than Mack,refer to the engine vendor’s publication.

Tampering With EmissionControl Systems ProhibitedThe Federal Clean Air Act prohibits theremoval or rendering inoperative of anydevice or element of design installed onor in a motor vehicle or motor vehicleengine in compliance with FederalEmission Regulations by:

1 Any person prior to its sale anddelivery to the ultimate purchaser, or

2 Any manufacturer or distributor afterits sale and delivery to the ultimatepurchaser, or

3 Any person engaged in the businessof repairing, servicing, selling,leasing, or trading motor vehicles ormotor vehicle engines following itssale and delivery to the ultimatepurchaser, or

4 Any person who operates a fleet ofmotor vehicles following its sale anddelivery to the ultimate purchaser.

NOTENote: For specifics of the prohibitedvehicle/engine modifications refer to theMack Body Builders documentation.

California Emission ControlWarranty StatementThe California Air Resources Board andMack Trucks are pleased to explain theemission control system warranty onyour 2017 / 2018 vehicle. In California,new motor vehicle engines must bedesigned, built and equipped to meetthe State’s stringent anti-smogstandards. Mack Trucks must warrantthe emission control system on yourengine for the period of time listedbelow provided there has been noabuse, neglect, or impropermaintenance of your engine. Youremission control system may includeparts such as the fuel-injection system,turbocharger assembly, electroniccontrol module and other emissionrelated assemblies. If an emission-related part of your engine is defective,the part will be repaired or replaced byMack Trucks. This is your EmissionControl System DEFECTS WARRANTY.

Owner Warranty ResponsibilitiesAs the motor vehicle engine owner, youare responsible for the performance of

the required maintenance listed in thismanual. Mack Trucks recommends thatyou retain all receipts coveringmaintenance of your vehicle, but MackTrucks cannot deny warranty solely forthe lack of receipts or for your failure toensure the performance of all scheduledmaintenance listed in other manualswhich were supplied with yourvehicle.You are responsible forpresenting your motor vehicle engine toa Mack Trucks dealer as soon as aproblem exists. The warranty repairsshould be completed in a reasonableamount of time, not to exceed 30 days.As the motor vehicle engine owner, youshould also be aware that Mack Trucksmay deny you warranty coverage if yourvehicle or a part has failed due to abuse,neglect, improper maintenance, orunapproved modifications. If you haveany questions regarding your warrantyrights and responsibilities, you shouldcontact Mack Trucks Warranty ActivitiesP.O. Box 26259, Greensboro, NC 27402,or the California Air Resources Board at9480 Telstar Avenue, El Monte,California 91731.

Federal, Canadian andCalifornia Emission ControlWarranty StatementTHIS WARRANTY IS EXPRESSLY INLIEU OF ALL OTHER WARRANTIES


INTRODUCTION


AND REPRESENTATIONS ORCONDITIONS, STATUTORY OROTHERWISE, EXPRESSED OR IMPLIEDINCLUDING, BUT NOT LIMITED TO,IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE.

The following engine components arecovered by the supplemental emissionscontrol system warranty policy asrequired by the Code of FederalRegulations, California Code ofRegulations, and the regulations underthe Canadian Environmental ProtectionAct, 1999.

Component Coverage1 Engine Turbocharger Assembly• Variable Geometry Turbo (VGT)Actuator

2 Charge Air Cooler (CAC)

3 Engine Control Module (ECM)

4 Injectors

5 EGR Cooler

6 EGR Valve and EGR Valve Control

7 EGR Venturi

8 Crankcase Breather (Does not includeCrankcase Pressure Sensor)

9 Crankcase Separator

10 Crankcase Tubing and Hoses beforeSeparator

11 Aftertreatment Wiring Harness (DPF)

12 Aftertreatment Wiring Harness (SCR)• Jumper to AHI Pressure Regulator• ACM Power Supply• Heater NOx Care• DEF Tank

13 Aftertreatment Control Module (ACM)

14 Aftertreatment Diesel ParticulateFilter (DPF) with Aftertreatment DieselOxidation Catalyst (DOC)• Aftertreatment Doser• Aftertreatment Fuel Shutoff Valve• Aftertreatment Fuel Pressure Sensor• Engine Exhaust Gas Temperature(EGT) Sensor• Aftertreatment DPF IntakeTemperature Sensor• Aftertreatment DPF Outlet TemperatureSensor• Aftertreatment DPF DifferentialPressure Sensor:

15 Sensors• Crankshaft Position (CKP) Sensor• Transmission Speed Sensor• Engine Coolant Temperature (ECT)Sensor• Intake Manifold Air Temperature/Pressure Sensor• Exhaust Gas Recirculation (EGR)Temperature Sensor• Aftertreatment Outlet NOx Sensor• Aftertreatment Intake NOx Sensor• Engine Exhaust Gas RecirculationDifferential Pressure Sensor

• Ambient Air Temperature (AAT) Sensor• Particulate Matter (PM) Sensor

16 SCR• Aftertreatment Selective CatalyticReduction (SCR) Catalyst• Aftertreatment Diesel Exhaust Fluid(DEF) Pump• Aftertreatment DEF Dosing AbsolutePressure Sensor• Aftertreatment DEF Return Valve• Aftertreatment DEF Dosing Valve• Aftertreatment DEF Tank• Aftertreatment DEF Tank Heater/Sender• Aftertreatment DEF Tank Heater• Aftertreatment DEF Tank Heater Valve• Aftertreatment DEF Tank TemperatureSensor• Aftertreatment DEF Level Sensor• Aftertreatment DEF Heated Lines• Aftertreatment DEF Quality Sensor

17 Instrument Cluster (Repair ofMicroprocessor)

18 Exhaust Gas Piping (fromMicroprocessor) Turbocharger toAftertreatment System)

The emission warranty for the dieselparticulate filter (DPF) and SCR Systemcovers defects in workmanship only.Normal maintenance, such as cleaningash from the filter at regularmaintenance intervals and cleaning theAftertreatment Fuel Injector on Diesel


INTRODUCTION


Oxidation Catalyst (DOC) DPF Systems,is not covered by the emission warranty.

NOTEIn response to customer requests, MackTrucks may build vehicles with enginessupplied by other manufacturers. In thesecases, each engine manufacturer throughits service organization, is responsible foremission control systems warranty on allparts of the engine assembly, asfurnished.

NOTEAny unauthorized adjustments to theemission control components can causesevere damage to the engine.

1 Repairs by Mack TrucksDealers, Sub-Dealers andService DealersRepairs covered by the EmissionControl Systems Warranty will beperformed by any authorized MackTrucks repair facility with no chargefor parts and labor (includingdiagnosis), using Mack parts for anypart of the emission control systemscovered by this warranty and founddefective.

2 In an EmergencyIn an Emergency where anauthorized Mack Trucks facility is not

available, repairs may be performedat any available serviceestablishment, or by the owner,using any replacement part, withinthe limitations of paragraphs 3 and 4in this section. An emergencycondition exists under this section if,after 30 days, repairs have not beencompleted or parts are not yetavailable. Mack Trucks will reimbursethe owner for such repairs that arecovered under this warranty,including diagnosis, not to exceedMack’s suggested retail price forparts replaced and labor chargesbased on Mack’s recommended timeallowance and geographicallyappropriate hourly labor rate.Replaced parts and paid invoicesmust be presented at a Mack Trucksfacility as a condition ofreimbursement for emergencyrepairs performed elsewhere.

3 Repairs by Non-Mack TrucksFacilitiesOwners may elect to havemaintenance, replacement, or repairof emission control systemsperformed by any repair facility, andmay elect to use parts other thanMack parts without invalidating thewarranty on other components, butthe cost of such service or parts will

not be covered by Mack Trucksunder its warranty.

4 Use of Non-Mack TrucksPartsUse of replacement parts which arenot the equivalent of Mack parts mayimpair the effectiveness of emissioncontrol systems. If other than Mackparts are used, the owner shouldobtain assurances that such partsare warranted by their manufacturerto be the equivalent of Mack parts inperformance and durability. Mackassumes no liability under thiswarranty with respect to parts otherthan Mack parts; however, the use ofnon-Mack parts does not invalidatethe warranty on other componentsunless non-Mack parts causedamage to warranted parts.

5 Maintenance andMaintenance RecordsThe vehicle owner is responsible forthe performance of all requiredmaintenance specified in thismanual. Mack Trucks will not deny awarranty claim solely because thereis no record of maintenance;however, Mack Trucks may deny awarranty claim if failure to performrequired maintenance results in thefailure of a warranted part. Receiptsor other records covering theperformance of scheduled


INTRODUCTION


maintenance should be retained toanswer questions that may ariseconcerning maintenance.Maintenance records should betransferred to subsequent owners ifthe vehicle is sold.

6 Items Not Covered by theEmission Control SystemsWarranty• Malfunctions caused by misuse,improper adjustments, modification,alteration, tampering, disconnection,improper or inadequate maintenanceand use of improper diesel fuel.

• Damage resulting from accident,acts of nature or other eventsbeyond the control of Mack Trucks.

• Inconvenience, loss of use of thevehicle, commercial loss of any kindincluding, but not limited to,consequential or incidentaldamages.

• Any vehicle in which the odometerhas been altered or damaged so thatmileage cannot be readilydetermined.

7 Customer AssistanceMack Trucks wishes to assure thatthe Emission Control SystemsWarranty is properly administered. Inthe event that owners do not receivethe warranty service to which they

believe they are entitled under theFederal, Canadian, or CaliforniaEmission Control Systems Warranty,they should contact the nearestMack Regional Office for assistance.

The address and telephone numberfor each Regional Office can befound at the front of this DriverManual.

NOTEIn the event that damage results fromunauthorized adjustments to any emissioncontrol system components, as evidencedby settings other than as specified, orbroken fastener seals, the cost ofrepairing such damage WILL NOT BECOVERED under warranty

Emission Green House GasComponent WarrantyMack Trucks warrants certain individualgreenhouse gas (GHG) components andcontrols of each new Mack vehiclecertified to the requirements of Chapter40 of the United States Code of FederalRegulations, Part 1037. Mack GHGcertified vehicles are warranted to bedesigned, built, and equipped so theyconform at the time of sale to theultimate purchaser to the requirementsof the Part and to be free from defects inmaterial and workmanship which, under

normal use and service, would cause thevehicle to fail to conform to therequirements of the Part up to theperiods specified, provided all MackTrucks maintenance and inspectionrequirements are followed. See yourlocal authorized Mack Trucks dealer forrecommended maintenance andinspection procedures. All warrantyperiods are calculated from the date inservice of the vehicle. All coverage is100% for parts and labor subject to thequalifications, limitations and exclusionsas noted.

LIMITATIONS AND EXCLUSIONS TOTHIS WARRANTY APPEAR ON THEFOLLOWING PAGES.THESELIMITATIONS AND EXCLUSIONS AREIMPORTANT AND MUST BE READ ANDUNDERSTOOD.

This warranty applies to new Mackvehicles certified to the requirements of40 CFR part 1037. Mack Trucks reservesthe right to make any changes in design,or make additions to or upon itsproducts, without incurring anyobligations to install the same changeson vehicles previously built.

Emissions ComponentsCoverage, VehicleNot Covered by the Emissions ControlSystem Warranty:


INTRODUCTION


• Malfunctions caused by misuse,improper adjustment, modificationalteration, tampering, disconnection,improper or inadequate maintenanceand use of improper diesel fuel or DEF.

• Damage resulting from accident, act ofnature or other events beyond thecontrol of Mack Trucks.

• Inconvenience, loss of use of thevehicle, commercial loss of any kindincluding, but not limited toconsequential or incidental damages.

• Any vehicle in which the odometer hasbeen altered or damaged so thatmileage cannot be readily determined.

THIS WARRANTY IS EXPRESSLY INLIEU OF ALL OTHER WARRANTIESAND REPRESENTATIONS ORCONDITIONS, STATUTORY OROTHERWISE, EXPRESSED OR IMPLIEDINCLUDING, BUT NOT LIMITED TO,IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE

Tires, Drive and Steer OnlyThe first 24 months or 38624 km (24,000miles) of vehicle operation, whicheveroccurs first, and applying only to the firstset of tires on the vehicle when deliveredto the ultimate purchaser. Subject to theterms and conditions of the tiremanufacturer’s warranty, excluding

retreads. Emissions related warrantycoverage only, refer to the specific tiremanufacturer’s warranty policy for otherterm lengths.

Source of Parts and RepairA repair shop or person of the owner’schoosing may maintain, replace, orrepair emission control devices andsystems.

Replacement of Tires that areGHG CertifiedThe original equipment tires installed onthis vehicle at the factory were certifiedto the U.S. EPA Greenhouse Gas (GHG)and NHTSA Fuel Efficiency regulations.Replacement of these tires should bewith a tire of equal or lower rollingresistance levels (TRRL or CRR). Pleaseconsult your tire supplier(s) forappropriate replacement tires.

Maintaining a GHG Certified TireIn order to maintain the certified rollingresistance of the tires which optimizefuel economy, the maintenanceprocedures provide by the tiremanufacturer must be followed.

All Other VehiclesEmission controls are warranted to 60months or 160934 km (100,000 miles),whichever occurs first.

Other Vehicle Components60 months or 160934 km (100,000miles), whichever occurs first.

Emission Control SystemWarrantyVehicles sold for use in California musthave the Operator’s Manual in thevehicle which contains the CaliforniaEmission System Warranty.

CoverageTires

Drive and Steer Only: The first 24months or 38624 km (24,000 miles) ofvehicle operation, whichever occursfirst, and applying only to the first set oftires on the vehicle when delivered to theultimate purchaser. Subject to the termsand conditions of the tire manufacturer’swarranty, excluding retreads. Emissionsrelated warranty coverage only, refer tothe specific tire manufacturer’s warrantypolicy for other term lengths.

Exterior Components: Highway TractorsOnly

Chassis Fairings, Ground EffectExtensions, Roof Deflectors, Cab SideDeflectors, Adjustable Roof Extensions,Side Deflector Extensions, BumperDeflectors, A-pillar Deflectors

60 Months or 160934 km (100,000Miles), whichever occurs first.


INTRODUCTION


Air Conditioning Components: Onlythose vehicles certified as “Tractors”according to the requirements ofChapter 40 of the Code of FederalRegulations, Part 1037.

Hoses, Compressor to CondenserHoses, Condenser to Drier Hoses, Drierto Climate Unit Hoses, Climate Unit toCompressor Hoses, Bunk Climate UnitReceiver Drier, Spring Loaded, 12 cubicin. A/C Compressor A/C Condenser A/CPressure Switches & Transducers MainClimate Unit Bunk Climate Unit

60 Months or 160934 km (100,000Miles), whichever occurs first.


INTRODUCTION

WARRANTY CERTIFICATES

Standard Truck WarrantyCertificateMack Trucks, warrants certain individual components of the new Mack truck to be free from defects in material and workmanshipunder normal use and service up to the periods as specified, provided all Mack Trucks, maintenance and inspection requirementsfound in the Operator’s Manuals and service manuals/instructions are followed. All warranty periods are calculated from date inservice. All coverage is 100% for parts and labor except as noted.

LIMITATIONS AND EXCLUSIONS TO THIS WARRANTY APPEAR ON THE REVERSE SIDE OF THIS CERTIFICATE.THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST BE READ AND UNDERSTOOD.

This warranty applies to Model Year 2016 and newer CHU, CXU, GU, LEU, LR, MRU and TD models manufactured by MackTrucks, operated in the United States and Canada. Specific coverage is based on the application and weight class as describedin the following chart:

Mack Trucks warrants certain individual components of the new Mack truck to be free from defects in material and workmanshipunder normal use and service up to the periods as specified, provided all Mack Trucks’ maintenance and inspection requirementsare followed. See your local authorized Mack dealer for recommended maintenance and inspection procedures. All warrantyperiods are calculated from date in service of the vehicle. All coverage is 100% for parts and labor subject to the qualifications,limitations, and exclusions as noted.

LIMITATIONS AND EXCLUSIONS TO THIS WARRANTY APPEAR ON THE FOLLOWING PAGES OF THIS CERTIFICATE.THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST BE READ AND UNDERSTOOD.This warranty applies to Model Year 2018 and newer models manufactured by Mack Trucks, operated in the United States andCanada. Specific coverage is based on the application and weight class as described in the following chart:

StandardNormal Duty

StandardHeavy Duty

StandardSevere Duty

Typical Vocation Line / Long Haul,Short Haul, or Pickup & Delivery

Heavy Line Haul,Construction, Refuse,Fire or Rescue Service

Heavy Construction, HeavyRefuse, Off-Road, HeavyHaul, Mining, Logging, orOil Field


INTRODUCTION


StandardNormal Duty

StandardHeavy Duty

StandardSevere Duty

Weight ClassQualifications

Vehicle must haveGVWR ≤ 63,000 lbs. (≤ 28 metric ton)orGCWR ≤ 110,000 lbs. (≤ 50 metric ton)

Vehicle must haveGVWR ≤ 80,000 lbs. (≤ 36 metric ton)orGCWR ≤ 143,000 lbs. (≤ 65 metric ton)

Vehicle must haveGAWR > 46,000 lbs. (> 21metric ton)orGVWR > 80,000 lbs. (> 36metric ton)orGCWR > 143,000 lbs. (>65 metric ton)

Basic Coverage * 12 months or100,000 miles (160 934 km)

12 months or100,000 miles (160 934 km)

12 months or100,000 miles (160 934km)

Chassis Towing Towing/Road Service coverage is limited to 90 days or 5,000 miles (8047 km), whicheveroccurs first, and to a single tow per incident to the nearest authorized Mack Trucks servicecenter. Charges in excess of $1,000.00 are not covered unless Mack OneCall™ service iscontacted and approves additional amounts prior to tow.

Not Applicable

Air Conditioning Air conditioning (sealed system only) is covered for 12 months with no mileage limitation.

Engine / Emission Not covered under this warranty certificate. See respective engine manufacturer’s warranty certificate.See paragraph 19 under Exclusions.

Transmission,Driveline, Rear Axle,Front Non-DriveSteer Axle

36 months or 350,000 miles (563 270 km)Covered Components are as follows:• Manual Transmission – Transmission Assembly• Driveline – Bearings, Hangers and Shafts• Rear Axle – Differential Carrier Assembly and Axle Housing• Front Non-Drive Steer Axle – Axle Beam, Steering Knuckle, and Tie Rod


Allison Automatic Transmissions are not covered under this warranty certificate. See paragraph 19 under Exclusions.

Mack Carrier & AxleHousing




Mack T300Transmission

60 months or750,000 miles (1 207 008 km)




INTRODUCTION


StandardNormal Duty

StandardHeavy Duty

StandardSevere Duty

mDRIVE™

TransmissionEngine Torque ≤ 1760 ft-lb: 60 months or750,000 miles (1 207 008 km) **Engine Torque > 1760 ft-lb: 36 months or500,000 miles (804 672 km)

mDRIVE™ 36 months or250,000 miles (402 336 km);mDRIVE™ HD: 36 monthswith no mileage limitation

mDRIVE™ : 12 months or100,000 miles (160 934km);mDRIVE™ HD: 24 monthswith no mileage limitation

mDRIVE™ Clutch 36 months or300,000 miles (482 803 km)

36 months or250,000 miles (402 336 km)mDRIVE™ and mDRIVE™ HD

mDRIVE™ : 12 months or100,000 miles (160 934km)mDRIVE™ HD: 24 monthsor250,000 miles (402 336km)

mDRIVE™ & T300Towing

Towing/Road Service on warrantable transmission failures is covered to 24 months or250,000 miles (402 336 km) whichever occurs first, and to a single tow per incident to thenearest authorized Mack Trucks service center. Charges in excess of $1,000.00 are notcovered unless Mack OneCall™ service is contacted and approves additional amountsprior to tow.

Not Applicable

Trunnion Bracket 36 months or 300,000 miles (482 803 km)Limited to Trunnion Bracket & Spindle, Suspension Trunnion (Except Bushings)

12 months or100,000 miles (160 934km)(same restrictions asNormal & Heavy)

Cab Structure 60 months or500,000 miles (804 672 km)



Internal CabCorrosion




Covered only where metal is perforated from the inside to the outside. See paragraph 18 under Exclusions.

Frame Rail /Crossmembers

60 months or500,000 miles (804 672 km)CHU/CXU Models Only: 72 months or750,000 miles (1 207 008 km)

36 months or300,000 miles (482 803 km)GU Model only: 60 months or500,000 miles (804 672 km)



INTRODUCTION


StandardNormal Duty

StandardHeavy Duty

StandardSevere Duty

Noise Emission LIFE OF VEHICLE: Mack Trucks, warrants to the first purchaser of this vehicle for purposes other than resale, and toeach subsequent purchaser, that this vehicle was designed, built and equipped to conform, at the time of sale to suchfirst purchaser, with all applicable U.S. EPA noise control regulations. This warranty is not limited to any vehicleparticular part, component, or system of the vehicle. Defects in the design, assembly, or any part, component orsystem of the vehicle, which at the time of sale to such first purchaser, caused noise emission levels to exceed Federalstandards, are covered by this warranty for the life of the vehicle. EXCLUSIONS: Failures which arise as a result oftampering rather than from defects in the design, assembly, or any part, components, or system of the vehicle are notcovered by this warranty.

*Covered for 30 Days: Fluorescent Lights or Ballast, Light Bulbs, Fuses, Wiper Blades, and All Filters (oil, fuel, air, etc.).Covered for 90 Days: Loose Fasteners, Leaking Fittings, or Loose Hose Clamps.**Includes engine torque to 1860 ft-lb with up to and including 455 HP.

THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST BE READ AND UNDERSTOOD.

LIMITATIONS – Mack Trucks obligation is limited to, at its sole option, repair or replacement of parts which are acknowledged byit to be defective. The defective parts or assemblies replaced shall become the property of Mack Trucks North America. Warrantyrepairs performed by an authorized Mack dealer in accordance with the terms of the warranty set forth herein are free of charge.Warranty consideration can only be given if the deficiency is brought to the attention of an authorized Mack dealer upon discoveryand the vehicle must be made available, in a timely fashion during the coverage period, for repair.

EXCLUSIONS:1. REPAIR: In the case of acknowledged defective Covered Parts, exchange with factory remanufactured parts may occur.Warranty repairs do not constitute an extension of any warranty period for any vehicle, component or part.2. DAMAGES: Damages due to misapplication, misuse, accidents, negligence, improper operations, alterations, storage ortransport, operation at excessive speeds, loading beyond the factory rated load capacity, failure to follow Mack Trucks’recommended inspection, maintenance, and service procedures, and improper or insufficient maintenance services are notcovered.3. PROGRESSIVE DAMAGE: Damages due to failure of operator to take reasonable precautions to mitigate damage are notcovered. Damages to a Covered Part due to failure of non-covered part are not covered. Coverage is limited to failure of aCovered Part directly causing failure of a non-covered part, where reasonable precautions were taken to mitigate damages.4. APPLICATION: The selling dealer is responsible for designating the correct application and/or specification for a vehicle sold toa customer. Damages due to misapplication, including but not limited to, failures of component parts of vehicles being operatedin excess of factory rated load capacities, or the use of a vehicle, component or part for a purpose for which it was not intendedare not covered.


INTRODUCTION


5. ALTERATIONS: Any vehicle, component or part repaired, altered, or inspected in any way, so as to adversely affect, in MackTrucks’ sole judgment, its stability, durability, or reliability, is not covered.6. NON-ORIGINAL EQUIPMENT: Any part of the vehicle that fails, malfunctions, or does not perform as a result of improperconversion or installation of bodies or equipment by other manufacturers or suppliers is not covered.7. MAINTENANCE AND PARTS CONSUMED: Maintenance and inspection requirements found in the Operator’s Manuals andservice manuals/instructions, including, but not limited to, engine tune-up, fuel system cleaning, replacement of lubricants andfilter elements, adjustments of the engine injection pump/transmission/brakes/linkages, as well as diagnosis, test time and allother adjustments must be followed and are not covered. Parts which are normally consumed or worn out during the vehicle’snormal service life and customarily replaced during usual maintenance service, including, but not limited to, mud flaps andbrackets, brake linings, clutch brake, and clutch linings, are not covered.8. PERFORMANCE COMPLAINTS: Performance complaints are not covered (including, but not limited to, low power and/or poorfuel economy). Coverage is limited to defects in material and workmanship of a Covered Part directly causing the performanceissue.9. WEAROUT: Mack Trucks does not cover normal wear of Covered Parts. Failures attributable to wear are excluded. For exampleand without limitation, the wear rate of parts in any engine or transmission, and especially those parts within the combustion areaand clutch housing area, will vary depending upon operating conditions and environment. Conditions, such as load, trailerconfiguration, road speed and road conditions, as well as the quality of fuel, lubrication oil, and all filters bear a direct relationshipto the wear rate and resulting life of parts. Depending upon the severity of these various conditions, parts wear and resultingfailure could occur within the time limit of the coverage.10. NON-GENUINE PARTS: Any failure of any vehicle, component or part caused by the use of parts and accessories, or majorassemblies and exchange units, which do not meet factory standards is not covered.11. ODOMETER READING: Any vehicle on which the actual mileage or hours cannot readily be determined, or on which theodometer, hour meter, or Electronic Control Unit has been disconnected, disabled, or altered, may not be covered by thiswarranty.12. ACCESS TO INFORMATION: Owner must allow Mack Trucks full access to all data stored in all Electronic Control Modules;failure to do so may result in the loss of warranty coverage.13. LABOR: Labor to remove and install a Covered Part is included only if a Mack Trucks authorized dealer originally installed theCovered Part. Labor for overtime and/or shift differential is not covered. Excessive labor for a warrantable repair due to the priorinstallation of equipment or body is not covered.14. MISC. EXPENSE: Meals, lodging, communications charges, travel time and expense, loss of cargo, downtime, loss of profit/revenue, rental vehicles, driver’s wages and other miscellaneous expenses are not covered. Shop supplies, lube oil, lubricants,sealers, anti-freeze, filter elements and labor performed by a non-approved location are not covered.15. ADDITIONAL COMPONENTS: Components or parts that are not installed by Mack Trucks, including winches, power take-offs,dumper, mixer and refuse assemblies, hoists and bodies or other special equipment are not covered. During a warrantable repair,


INTRODUCTION


additional time to remove any customer installed components will not be covered under warranty. Mack Trucks’ factorymanufacturing records will be determinative as to factory installed components.16. TOWING: Unless expressly provided in this Warranty Certificate, expenses for towing or road service are not covered. Failurescaused by improper towing technique are not covered.17. SUSPENSION PARTS: Suspension parts, including but not limited to rubber bushings, torque rod bushings, spring pins andbushings, and greased lubrication points that fail due to improper maintenance, abnormally severe service or abuse are notcovered.18. CAB STRUCTURE AND CORROSION: Cab structural defects or cab corrosion that occurs in areas of the cab that previouslywere damaged, repaired, altered or modified are not covered. Cab corrosion where metal is perforated from the outside to theinside is not covered.19. VENDOR ENGINES, ALLISON AUTOMATIC TRANSMISSIONS and ALTERNATE FUEL STORAGE AND DELIVERY SYSTEMS:Vendor engines, Allison automatic transmissions and alternate fuel (CNG/LNG/DME) fuel storage/delivery components used inMack trucks are warranted by their respective manufacturers and not by Mack Trucks, Inc. Refer to the manufacturers’ warrantystatements.20. OIL CONSUMPTION: Before a claim based upon excessive oil consumption will be considered, the owner must provide proofthat all recommended maintenance has been performed and submit adequate documentation to show that oil consumptionexceeds Mack Trucks’ published standards. Under no circumstances will warranty pay for repairs related to excessive oilconsumption after the earlier of 24 months, 250,000 miles, 402,000 kilometers, or 6,250 engine hours.21. ENVIRONMENTAL DAMAGE: Parts made out of cloth, leather, wood, rubber, synthetics, paint or chrome which have beenaffected by exposure to the elements or chemical influence including, but not limited to, road salts/chemicals, industrial fall-out orthe use of improper cleaners, polishes and/or waxes are not covered.22. ALIGNMENT: Alignment of axle(s), balance of tires, changing of axle camber, caster, toe and thrust angle are not covered.23. GLASS: Glass breakage and scratches are not covered unless physical proof of manufacturing responsibility is established.24. TIRES: Tires are not covered by this warranty, but may be covered by separate warranties given by their respectivemanufacturers.25. CHANGES: Mack Trucks reserves the right to make any changes in design, or make additions to or upon its products, withoutincurring any obligations to install the same changes on vehicles previously built.

THIS WARRANTY IS MADE EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, REPRESENTATIONS OR CONDITIONS,STATUTORY OR OTHERWISE, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY ORCONDITION OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATION ORLIABILITY ON THE PART OF THE MANUFACTURER INCLUDING, WITHOUT LIMITATION OF THE FOREGOING,CONSEQUENTIAL, INDIRECT, AND INCIDENTAL DAMAGES. MANUFACTURER NEITHER ASSUMES NOR AUTHORIZES ANYPERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF VEHICLES, COMPONENTS ORPARTS.


INTRODUCTION


Standard Engine WarrantyCertificate (EPA 17 andnewer)Mack Trucks warrants certain individual components of each new Mack MP®7, MP®8, and MP®10 EPA 17 and newer emissionengine in a new Mack truck to be free from defects in material and workmanship under normal use and service up to the periodsspecified, provided all Mack Trucks' maintenance and inspection requirements are followed. See your local authorized Mackdealer for recommended maintenance and inspection procedures. All warranty periods are calculated from the date in service ofthe vehicle. All coverage is 100% for parts and labor subject to the qualifications, limitations, and exclusions as noted.

LIMITATIONS AND EXCLUSIONS TO THIS WARRANTY APPEAR ON THE FOLLOWING PAGES OF THIS CERTIFICATE.THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST BE READ AND UNDERSTOOD.

This warranty applies to only new Mack MP®7, MP®8, and MP®10 engines meeting EPA 17 and newer emission requirements innew Mack trucks operated in the United States and Canada.

Standard Mack Engine Components Coverage: 24 months or 250,000 miles (402 336 km), whichever occurs first, unlessotherwise noted.

Major Components Coverage: 60 months or 500,000 miles (804 672 km), whichever occurs first.

USE OF IMPROPER OR UNAPPROVED FUEL OR ENGINE OIL WILL VOID THE ENGINE AND AFTERTREATMENT SYSTEM(DIESEL PARTICULATE FILTER) WARRANTIES. EPA 17 EMISSION MACK ENGINES REQUIRE THE USE OF MACKSPECIFICATION EOS 4.5 HIGH PERFORMANCE DIESEL ENGINE OIL AND ULTRA LOW SULFUR DIESEL (ULSD) FUEL.

USE OF FLUIDS OTHER THAN API CERTIFIED DIESEL EXHAUST FLUID (DEF) WILL COMPROMISE AFTERTREATMENTSYSTEM PERFORMANCE, INCREASE EMISSIONS, AND MAY IMPACT THIS TRUCK’S PRODUCT WARRANTIES.

SEE FOLLOWING TABLE FOR SPECIFIC COVERAGES:

Covered Standard Components List:24 Months or 250,000 Miles (402 336 km )

Qualifications and Limitations

Air Compressor Includes: Sprocket and Mounting Bolts

Bearings All internally lubricated Bearings and Bushings only.

Camshaft, Caps, and Bolts Failures resulting from the Valve and Injector adjustments not being maintained properly areNOT covered. Normal maintenance adjustments are NOT covered.

Connecting Rods, Caps, and Bolts


INTRODUCTION




Coolant Duct Cover

Crankcase Ventilation Assembly

Crankshaft

Crankshaft Hub

Cylinder Block Includes: Casting, Main Caps, and Bolts

Cylinder Block Heater

Cylinder Head Includes: Assembly, Casting, Bolts, Plugs, and Sleeves

Diesel Particulate Filter Assembly (DPF) /Diesel Oxidation Catalyst (DOC) / SelectiveCatalytic Reduction (SCR)

Includes: Aftertreatment Hydrocarbon Injector (AHI), Aftertreatment Wiring Harness,Aftertreatment Control Module, Diffuser Pipe (AHI Mounting), Fuel Lines to AHI Injector, AHIShutoff Valve, AHI Fuel Pressure Sensor, Pre-Catalyst Temperature Sensor, Post-CatalystTemperature Sensor, downstream DPF Temperature Sensor, Differential Pressure Sensor,Particulate Matter (PM) Sensor, SCR Assembly, DEF Pump Assembly (Pump RevertingValve, Pump Pressure Sensor), DEF Injector, DEF Tank Heating Control Valve, NOx Sensor(SCR Inlet and Outlet)

EGR (Exhaust Gas Recirculation) Components All components including Clamps, Control Valve, Cooler, Fittings, Gaskets, Mixer, Pipes,and EGR Wiring Harness. Excludes: EGR Cooler Vibration Damper which is a maintenanceitem.

Electrical EA Harness Supplied with Engine From EECU to Sensors and Injectors and Actuators

Engine Electronic Control Unit (EECU)

Engine Brake Mechanism - PowerLeash™ Factory Installed OnlyIncludes: PowerLeash™ Control Valve and PowerLeash™ Rocker ArmsTurbo Compound (TC) Engine: Closed Loop Butterfly (CLB)

Exhaust Manifold Includes: Casting, Joint Seals, Rings, and Wraps

Fan Belt Tensioner Assembly and Bracket Excludes: Fan Belt

Flywheel Includes: Housing and Ring Gear

Fuel Filter Housing Excludes: Filters

Fuel Injection System Includes: Injectors, common rail assembly (Electronic Fuel Pressure Regulator and PressureSensor)


INTRODUCTION




Fuel Transfer Pump

Gaskets, Seals, O Rings, and Silicon Sealant

Gears All internally lubricated Gears only (Timing and Idler Gears)

Hoses and Lines, Supplied with Engine Fluid carrying: Engine to Engine Mounted

Idler Pulleys

Intake Manifold and Throttle Assembly

Ladder Frame

Oil Cooler Engine Oil Cooler Only

Oil Fill Tube and Cap

Oil Filter Housing Excludes: Oil Filters

Oil Pan

Oil Pump

Piston Assembly Includes: Cooler Nozzles, Liners, Pistons, and Rings

Pneumatic Control System TC Engine: Air Valve Unit, Buffer Valve Unit, and Check Valve

Power Steering Pump

Pre-Heater Factory Installed Only. Includes: Preheat Relay, Terminals, and Power Cables

PTO Drive / REPTO (Rear Engine MountedPTO Drive)

Factory Installed Only. Excludes: All Pumps or Drive Gears

Rocker Arm Assembly and Shafts Includes: PowerLeash™ Rockers and non- PowerLeash™ Rockers. Failures resulting fromthe Valve and Injector Adjustments not being maintained properly are NOT covered. Normalmaintenance Adjustments are NOT covered.

Sensors (On Engine) Includes: Coolant Temperature, Crankcase Pressure, Crankshaft (Engine Timing), EGRTemperature and Pressure, Engine Oil Level and Temperature, Engine Oil Pressure, EnginePosition (Camshaft), Fuel Pressure and Temperature, Intake Boost Pressure andTemperature, and Inlet Manifold Air (Temperature and Pressure)

Starter Motor

Thermostat (Coolant) Includes: Thermostat Side Cover


INTRODUCTION




Timing Gear Cover and Mounting Plate

Towing Towing/Road Service on warrantable engine failures is covered to 24 months or 250,000miles (402 336 km) whichever occurs first, and to a single tow per incident to the nearestauthorized Mack service center. Charges in excess of $1,000.00 are not covered unlessMack OneCall™ service is contacted and approves additional amounts prior to tow.

Turbocharger Assembly Includes: VGT Actuator Module and Turbo Compound (TC) Assembly, if included

Valve Assembly Includes: Guides, Keepers, Rotators, Seats, Springs and Valves. Failures resulting from theValve Adjustments not being maintained properly are NOT covered. Normal maintenanceadjustments are NOT covered.

Valve Cover

Valve Yokes (Bridge) and Pins Failures resulting from the Valve Adjustments not being maintained properly are NOTcovered. Normal maintenance adjustments are NOT covered.

Vibration Dampers and Bolts

Water Pump Assembly

Covered Major Components List: 60 Months or500,000 Miles (804 672 km )


Camshaft, Caps and Bolts Failures resulting from the Valve & Injector Adjustments not being maintained properly areNOT covered. Normal maintenance adjustments are NOT covered.

Connecting Rods, Caps, and Bolts

Crankshaft Forging

Cylinder Block Casting, Main Caps, and Bolts

Cylinder Head Casting and Bolts

Exhaust Manifold Casting

Flywheel Housing

Gears All internally lubricated Gears only (Timing and Idler Gears)

Intake Manifold Housing

Ladder Frame


INTRODUCTION


Covered Major Components List: 60 Months or500,000 Miles (804 672 km )


Thermostat Housing

Timing Gear Cover and Mounting Plate



EXCLUSIONS:1. REPAIR: In the case of acknowledged defective Covered Parts, exchange with factory remanufactured parts may occur.Warranty repairs do not constitute an extension of any warranty period for any vehicle, component or part.2. DAMAGES: Damages due to misapplication, misuse, accidents, negligence, improper operations, alterations, storage ortransport, operation at excessive speeds, loading beyond the factory rated load capacity, failure to follow Mack Trucks’recommended inspection, maintenance, and service procedures, and improper or insufficient maintenance services are notcovered.3. PROGRESSIVE DAMAGE: Damages due to failure of operator to take reasonable precautions to mitigate damage are notcovered. Damages to a Covered Part due to failure of non-covered part are not covered. Coverage is limited to failure of aCovered Part directly causing failure of a non-covered part, where reasonable precautions were taken to mitigate damages.4. APPLICATION: The selling dealer is responsible for designating the correct application and/or specification for a vehicle sold toa customer. Damages due to misapplication, including but not limited to, failures of component parts of vehicles being operatedin excess of factory rated load capacities, or the use of a vehicle, component or part for a purpose for which it was not intendedare not covered.5. ALTERATIONS: Any vehicle, component or part repaired, altered, or inspected in any way, so as to adversely affect, in MackTrucks’ sole judgment, its stability, durability, or reliability, is not covered.6. NON-ORIGINAL EQUIPMENT: Any part of the vehicle that fails, malfunctions, or does not perform as a result of improperconversion or installation of bodies or equipment by other manufacturers or suppliers is not covered.7. MAINTENANCE AND PARTS CONSUMED: Maintenance and inspection requirements found in the Operator’s Manuals andservice manuals/instructions, including, but not limited to, engine tune-up, fuel system cleaning, replacement of lubricants andfilter elements, adjustments of the engine injection pump/transmission/brakes/linkages, as well as diagnosis, test time and allother adjustments must be followed and are not covered. Parts which are normally consumed or worn out during the vehicle’s


INTRODUCTION


normal service life and customarily replaced during usual maintenance service, including, but not limited to, mud flaps andbrackets, brake linings, clutch brake, and clutch linings, are not covered.8. PERFORMANCE COMPLAINTS: Performance complaints are not covered (including, but not limited to, low power and/or poorfuel economy). Coverage is limited to defects in material and workmanship of a Covered Part directly causing the performanceissue.9. WEAROUT: Mack Trucks does not cover normal wear of Covered Parts. Failures attributable to wear are excluded. For exampleand without limitation, the wear rate of parts in any engine or transmission, and especially those parts within the combustion areaand clutch housing area, will vary depending upon operating conditions and environment. Conditions, such as load, trailerconfiguration, road speed and road conditions, as well as the quality of fuel, lubrication oil, and all filters bear a direct relationshipto the wear rate and resulting life of parts. Depending upon the severity of these various conditions, parts wear and resultingfailure could occur within the time limit of the coverage.10. NON-GENUINE PARTS: Any failure of any vehicle, component or part caused by the use of parts and accessories, or majorassemblies and exchange units, which do not meet factory standards is not covered.11. ODOMETER READING: Any vehicle on which the actual mileage or hours cannot readily be determined, or on which theodometer, hour meter, or Electronic Control Unit has been disconnected, disabled, or altered, may not be covered by thiswarranty.12. ACCESS TO INFORMATION: Owner must allow Mack Trucks full access to all data stored in all Electronic Control Modules;failure to do so may result in the loss of warranty coverage.13. LABOR: Labor to remove and install a Covered Part is included only if a Mack Trucks authorized dealer originally installed theCovered Part. Labor for overtime and/or shift differential is not covered. Excessive labor for a warrantable repair due to the priorinstallation of equipment or body is not covered.14. MISC. EXPENSE: Meals, lodging, communications charges, travel time and expense, loss of cargo, downtime, loss of profit/revenue, rental vehicles, driver’s wages and other miscellaneous expenses are not covered. Shop supplies, lube oil, lubricants,sealers, anti-freeze, filter elements and labor performed by a non-approved location are not covered.15. ADDITIONAL COMPONENTS: Components or parts that are not installed by Mack Trucks, including winches, power take-offs,dumper, mixer and refuse assemblies, hoists and bodies or other special equipment are not covered. During a warrantable repair,additional time to remove any customer installed components will not be covered under warranty. Mack Trucks’ factorymanufacturing records will be determinative as to factory installed components.16. TOWING: Unless expressly provided in this Warranty Certificate, expenses for towing or road service are not covered. Failurescaused by improper towing technique are not covered.17. SUSPENSION PARTS: Suspension parts, including but not limited to rubber bushings, torque rod bushings, spring pins andbushings, and greased lubrication points that fail due to improper maintenance, abnormally severe service or abuse are notcovered.


INTRODUCTION


18. CAB STRUCTURE AND CORROSION: Cab structural defects or cab corrosion that occurs in areas of the cab that previouslywere damaged, repaired, altered or modified are not covered. Cab corrosion where metal is perforated from the outside to theinside is not covered.19. VENDOR ENGINES, ALLISON AUTOMATIC TRANSMISSIONS and ALTERNATE FUEL STORAGE AND DELIVERY SYSTEMS:Vendor engines, Allison automatic transmissions and alternate fuel (CNG/LNG/DME) fuel storage/delivery components used inMack trucks are warranted by their respective manufacturers and not by Mack Trucks, Inc. Refer to the manufacturers’ warrantystatements.20. OIL CONSUMPTION: Before a claim based upon excessive oil consumption will be considered, the owner must provide proofthat all recommended maintenance has been performed and submit adequate documentation to show that oil consumptionexceeds Mack Trucks’ published standards. Under no circumstances will warranty pay for repairs related to excessive oilconsumption after the earlier of 24 months, 250,000 miles, 402,000 kilometers, or 6,250 engine hours.21. ENVIRONMENTAL DAMAGE: Parts made out of cloth, leather, wood, rubber, synthetics, paint or chrome which have beenaffected by exposure to the elements or chemical influence including, but not limited to, road salts/chemicals, industrial fall-out orthe use of improper cleaners, polishes and/or waxes are not covered.22. ALIGNMENT: Alignment of axle(s), balance of tires, changing of axle camber, caster, toe and thrust angle are not covered.23. GLASS: Glass breakage and scratches are not covered unless physical proof of manufacturing responsibility is established.24. TIRES: Tires are not covered by this warranty, but may be covered by separate warranties given by their respectivemanufacturers.25. CHANGES: Mack Trucks reserves the right to make any changes in design, or make additions to or upon its products, withoutincurring any obligations to install the same changes on vehicles previously built.



INTRODUCTION


Standard EmissionsComponent WarrantyCertificate (EPA 17)Mack Trucks warrants certain individual components of the Emission Control system in a new Mack truck equipped with a newMack MP®7, MP®8, and MP®10 EPA 17 emission engine in a new Mack truck to be free from defects in material andworkmanship under normal use and service up to the periods specified, provided all Mack Trucks’ maintenance and inspectionrequirements are followed. See your local authorized Mack Trucks dealer for recommended maintenance and inspectionprocedures. All warranty periods are calculated from the date in service of the vehicle. All coverage is 100% for parts and laborsubject to the qualifications, limitations, and exclusions as noted.

LIMITATIONS AND EXCLUSIONS TO THIS WARRANTY APPEAR ON THE FOLLOWING PAGES OF THIS CERTIFICATE.THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST BE READ AND UNDERSTOOD.

This warranty applies to new MP®7, MP®8, and MP®10 engines meeting EPA 17 emission requirements in new Mack trucksoperated in the United States and Canada.

Emission Control System WarrantyEngine emission controls manufactured by Mack Trucks are warranted to 60 months or 100,000 miles (160 934 km), whicheverfirst occurs. Vehicles sold for use in California must have the Operator’s Manual in the vehicle which contains the CaliforniaEmission System Warranty.

USE OF IMPROPER OR UNAPPROVED FUEL OR ENGINE OIL WILL VOID THE ENGINE AND AFTERTREATMENT SYSTEM(DIESEL PARTICULATE FILTER) WARRANTIES. MACK ENGINES REQUIRE THE USE OF MACK SPECIFICATION EOS 4.5 HIGHPERFORMANCE DIESEL ENGINE OIL AND ULTRA LOW SULFUR DIESEL (ULSD) FUEL.

USE OF FLUIDS OTHER THAN API CERTIFIED DIESEL EXHAUST FLUID (DEF) WILL COMPROMISE AFTERTREATMENTSYSTEM PERFORMANCE, INCREASE EMISSIONS, AND MAY IMPACT THIS TRUCK'S PRODUCT WARRANTIES.

SEE FOLLOWING TABLE FOR SPECIFIC COVERAGES:

Covered Emission Components List: 60Months or100,000 Miles (160 934 km)


Aftertreatment Control Module (ACM)


INTRODUCTION




Aftertreatment Diesel Particulate Filter (DPF)with Aftertreatment Diesel Oxidation Catalyst(DOC)

Includes: Aftertreatment Doser, Aftertreament Doser Module (Aftertreatment Fuel ShutoffValve, Aftertreatment Fuel Pressure Sensor), Engine Exhaust Gas Temperature (EGT) Sensor,Aftertreatment DPF Intake Temperature Sensor, Aftertreatment DPF Outlet TemperatureSensor, Aftertreatment DPF Differential Pressure Sensor

Aftertreatment Wiring Harness (DPF)

Aftertreatment Wiring Harness (SCR) Includes: Jumper to AHI Pressure Regulator, ACM Power Supply, Heater NOx Care, DEFTank

Charge Air Cooler (CAC)

Crankcase Breather Excludes: Crankcase Pressure Sensor

Crankcase Separator

Crankcase Tubing & Hoses before Separator

EGR Cooler

EGR Valve and EGR Valve Control

EGR Venturi

Engine Electronic Control Unit (EECU) For the failure to be covered under Emission Components, the failure must affect theemissions of the unit.

Engine Turbocharger Assembly Includes: Variable Geometry Turbo (VGT) Actuator

Exhaust Gas Piping From Turbocharger to Aftertreatment System

Injectors

Instrument Cluster Limited to repair of Microprocessor, MIL, Real Time Clock, DEF Gauge, DEF Lamp

Selective Catalytic Reduction (SCR) Includes: Aftertreatment Selective Catalytic Reduction (SCR) Catalyst, Aftertreatment DieselExhaust Fluid (DEF) Pump (Aftertreatment DEF Dosing Absolute Pressure Sensor,Aftertreatment DEF Return Valve), Aftertreatment DEF Dosing Valve, Aftertreatment DEFTank, Aftertreatment DEF Tank Heater/Sender, Aftertreatment DEF Tank Heater,Aftertreatment DEF Tank Heater Valve, Aftertreatment DEF Tank Temperature Sensor,Aftertreatment DEF Level Sensor, Aftertreatment DEF Heated Lines, Aftertreatment DEFQuality Sensor

Sensor, Aftertreatment Intake NOx


INTRODUCTION




Sensor, Aftertreatment Outlet NOx

Sensor, Ambient Air Temperature Sensor

Sensor, Crankshaft Position (CKP)

Sensor, Engine Coolant Temperature (ECT)

Sensor, Engine Exhaust Gas Recirculation(EGR)Differential Pressure SensorSensor, Engine Exhaust Gas Recirculation(EGR)TemperatureSensor, Intake Manifold Air Temperature/PressureSensor, Particulate Matter (PM)

GHG Covered Component24 Months or 24,000 Miles (38 624 km)


Tires Drive and Steer Only: The first 24 months or 24,000 miles (38 624 km) of vehicle operation,whichever occurs first, and applying only to the first set of tires on the vehicle whendelivered to the ultimate purchaser.Subject to the terms and conditions of the tire manufacturer’s warranty, excluding retreads.Emissions related warranty coverage only; Refer to the specific tire manufacturer’s warrantypolicy for other term lengths.


INTRODUCTION


GHG Covered Components60 Months or 100,000 Miles (160 934 km),whichever occurs first.(Only those vehicles certified as “HighwayTractors” according to the requirements ofChapter 40 of the Code of Federal Regulations,Part 1037)


Exterior Components Limited to: Chassis Fairings, Ground Effect Extensions, Roof Deflectors, Cab SideDeflectors, Adjustable Roof Extensions, Side Deflector Extensions, Bumper Deflectors, A-pillar Deflectors

Air Conditioning Components Limited to: A/C Compressor, A/C Condenser, A/C Pressure Switches and Transducers,Bunk Climate Unit, Hoses (Compressor to Condenser, Condenser to Drier, Drier to ClimateUnit, Climate Unit to Compressor, Bunk Climate Unit), Main Climate Unit, Receiver Drier



EXCLUSIONS:1. REPAIR: In the case of acknowledged defective Covered Parts, exchange with factory remanufactured parts may occur.Warranty repairs do not constitute an extension of any warranty period for any vehicle, component or part.2. DAMAGES: Damages due to misapplication, misuse, accidents, negligence, improper operations, alterations, storage ortransport, operation at excessive speeds, loading beyond the factory rated load capacity, failure to follow Mack Trucks’recommended inspection, maintenance, and service procedures, and improper or insufficient maintenance services are notcovered.3. PROGRESSIVE DAMAGE: Damages due to failure of operator to take reasonable precautions to mitigate damage are notcovered. Damages to a Covered Part due to failure of non-covered part are not covered. Coverage is limited to failure of aCovered Part directly causing failure of a non-covered part, where reasonable precautions were taken to mitigate damages.4. APPLICATION: The selling dealer is responsible for designating the correct application and/or specification for a vehicle sold toa customer. Damages due to misapplication, including but not limited to, failures of component parts of vehicles being operatedin excess of factory rated load capacities, or the use of a vehicle, component or part for a purpose for which it was not intendedare not covered.


INTRODUCTION


5. ALTERATIONS: Any vehicle, component or part repaired, altered, or inspected in any way, so as to adversely affect, in MackTrucks’ sole judgment, its stability, durability, or reliability, is not covered.6. NON-ORIGINAL EQUIPMENT: Any part of the vehicle that fails, malfunctions, or does not perform as a result of improperconversion or installation of bodies or equipment by other manufacturers or suppliers is not covered.7. MAINTENANCE AND PARTS CONSUMED: Maintenance and inspection requirements found in the Operator’s Manuals andservice manuals/instructions, including, but not limited to, engine tune-up, fuel system cleaning, replacement of lubricants andfilter elements, adjustments of the engine injection pump/transmission/brakes/linkages, as well as diagnosis, test time and allother adjustments must be followed and are not covered. Parts which are normally consumed or worn out during the vehicle’snormal service life and customarily replaced during usual maintenance service, including, but not limited to, mud flaps andbrackets, brake linings, clutch brake, and clutch linings, are not covered.8. PERFORMANCE COMPLAINTS: Performance complaints are not covered (including, but not limited to, low power and/or poorfuel economy). Coverage is limited to defects in material and workmanship of a Covered Part directly causing the performanceissue.9. WEAROUT: Mack Trucks does not cover normal wear of Covered Parts. Failures attributable to wear are excluded. For exampleand without limitation, the wear rate of parts in any engine or transmission, and especially those parts within the combustion areaand clutch housing area, will vary depending upon operating conditions and environment. Conditions, such as load, trailerconfiguration, road speed and road conditions, as well as the quality of fuel, lubrication oil, and all filters bear a direct relationshipto the wear rate and resulting life of parts. Depending upon the severity of these various conditions, parts wear and resultingfailure could occur within the time limit of the coverage.10. NON-GENUINE PARTS: Any failure of any vehicle, component or part caused by the use of parts and accessories, or majorassemblies and exchange units, which do not meet factory standards is not covered.11. ODOMETER READING: Any vehicle on which the actual mileage or hours cannot readily be determined, or on which theodometer, hour meter, or Electronic Control Unit has been disconnected, disabled, or altered, may not be covered by thiswarranty.12. ACCESS TO INFORMATION: Owner must allow Mack Trucks full access to all data stored in all Electronic Control Modules;failure to do so may result in the loss of warranty coverage.13. LABOR: Labor to remove and install a Covered Part is included only if a Mack Trucks authorized dealer originally installed theCovered Part. Labor for overtime and/or shift differential is not covered. Excessive labor for a warrantable repair due to the priorinstallation of equipment or body is not covered.14. MISC. EXPENSE: Meals, lodging, communications charges, travel time and expense, loss of cargo, downtime, loss of profit/revenue, rental vehicles, driver’s wages and other miscellaneous expenses are not covered. Shop supplies, lube oil, lubricants,sealers, anti-freeze, filter elements and labor performed by a non-approved location are not covered.15. ADDITIONAL COMPONENTS: Components or parts that are not installed by Mack Trucks, including winches, power take-offs,dumper, mixer and refuse assemblies, hoists and bodies or other special equipment are not covered. During a warrantable repair,


INTRODUCTION


additional time to remove any customer installed components will not be covered under warranty. Mack Trucks’ factorymanufacturing records will be determinative as to factory installed components.16. TOWING: Unless expressly provided in this Warranty Certificate, expenses for towing or road service are not covered. Failurescaused by improper towing technique are not covered.17. SUSPENSION PARTS: Suspension parts, including but not limited to rubber bushings, torque rod bushings, spring pins andbushings, and greased lubrication points that fail due to improper maintenance, abnormally severe service or abuse are notcovered.18. CAB STRUCTURE AND CORROSION: Cab structural defects or cab corrosion that occurs in areas of the cab that previouslywere damaged, repaired, altered or modified are not covered. Cab corrosion where metal is perforated from the outside to theinside is not covered.19. VENDOR ENGINES, ALLISON AUTOMATIC TRANSMISSIONS and ALTERNATE FUEL STORAGE AND DELIVERY SYSTEMS:Vendor engines, Allison automatic transmissions and alternate fuel (CNG/LNG/DME) fuel storage/delivery components used inMack trucks are warranted by their respective manufacturers and not by Mack Trucks, Inc. Refer to the manufacturers’ warrantystatements.20. OIL CONSUMPTION: Before a claim based upon excessive oil consumption will be considered, the owner must provide proofthat all recommended maintenance has been performed and submit adequate documentation to show that oil consumptionexceeds Mack Trucks’ published standards. Under no circumstances will warranty pay for repairs related to excessive oilconsumption after the earlier of 24 months, 250,000 miles, 402,000 kilometers, or 6,250 engine hours.21. ENVIRONMENTAL DAMAGE: Parts made out of cloth, leather, wood, rubber, synthetics, paint or chrome which have beenaffected by exposure to the elements or chemical influence including, but not limited to, road salts/chemicals, industrial fall-out orthe use of improper cleaners, polishes and/or waxes are not covered.22. ALIGNMENT: Alignment of axle(s), balance of tires, changing of axle camber, caster, toe and thrust angle are not covered.23. GLASS: Glass breakage and scratches are not covered unless physical proof of manufacturing responsibility is established.24. TIRES: Tires are not covered by this warranty, but may be covered by separate warranties given by their respectivemanufacturers.25. CHANGES: Mack Trucks reserves the right to make any changes in design, or make additions to or upon its products, withoutincurring any obligations to install the same changes on vehicles previously built.



DRIVING TIPS

DRIVING TIPS

DRIVER ENVIRONMENT

• Always wear a seat belt• Adjust the driver seat and mirrors for a good driving

position• Use the cab's storage compartments


DRIVING TIPS

DRIVER ENVIRONMENT

Driver EnvironmentFor your safety at work, always wear aseat belt. Remember that it is a legalrequirement.

Driving PositionIt is important that you sit comfortablyand have good visibility while you aredriving. Arms and back must have arestful, natural posture. So take the timeto adjust mirrors, steering wheel, andseat to an optimal position beforedriving.

When driving long distances, changeyour driving position at regular intervals.Keep the backrest and head restraintupright when driving on uneven roadsurfaces to avoid back and neck injuries.

Climate SystemYou can use the climate controlrecirculation function to raise or lowerthe temperature in the cab.


DRIVING TIPS

STARTING

• Cold starting, use engine block heater• Warm up the truck by driving at low engine speeds

instead of running it at idling speed


DRIVING TIPS

STARTING

StartingWhen you start your truck, there areseveral things you can do to save fueland reduce wear on the truck.

Cold StartingYou can avoid cold starting by using theengine block heater.

If you start with a cold engine youshould switch on the air intake heatingfunction in your truck. The engine willthen be supplied with preheated airwhich results in easier and moreenvironmentally-friendly starting.

Never rev a cold engine. Warm up theengine by driving gently at low enginespeeds instead of letting it run at idlingspeed while stationary.


DRIVING TIPS

DRIVING IN AN URBAN AREA

• Plan your driving• Use the truck's mirrors and direction indicators• Always watch out for pedestrians


DRIVING TIPS

DRIVING IN AN URBAN AREA

Driving in an Urban AreaWhen driving in an urban area, there areseveral tricks that can enhanceefficiency.

Smart DrivingPlan your route to avoid unnecessarystops. You save more fuel and thetruck's service brakes, by using thetruck's auxiliary brakes as often as ispossible. If you have cruise control, youshould not use it in heavy traffic. If youuse it incorrectly it can lead tounnecessary braking and acceleration,which results in increased fuelconsumption.

Think about Cyclists andPedesteriansMany serious accidents occur betweentrucks and the softer road users such ascyclists and pedestrians. Correctlyadjusted mirrors give you good visibilityaround the vehicle, but be aware of theblind spots behind and in front of thetruck also on the passenger side.

Reverse Warning UnitThis vehicle is equipped with a ReverseWarning Unit (Back-Up Alarm) to alertpersons in the vicinity that the vehicle ismoving in reverse.

WARNINGThis vehicle is equipped with a Back-UpAlarm.ALARM MUST SOUND!Failure to maintain a clear view in thedirection of travel could result in seriousinjury or death.The operator is responsible for the safeoperation of this vehicle.


DRIVING TIPS

DRIVING ON A HIGHWAY

• Plan your driving• Maintain an even, steady speed when possible


DRIVING TIPS

DRIVING ON A HIGHWAY

Driving on a HighwayThere are many ways to enhanceefficiency when driving on a highway.

Remember that roads with many uphillinclines and bends result in higher fuelconsumption. For this reason, it is oftenwise to plan the most efficient routeahead of time.

Adapted SpeedIt is important to maintain a correctlyadapted speed. Higher speeds result inincreased wind resistance and increasedfuel consumption. Remember thatdoubled speed results in quadrupledwind resistance. You can reduce thetrucks wind resistance and thereforereduce fuel consumption by using aspoiler.

Gear Changing

Use the Auxiliary BrakesYou can reduce the wear on the truck'sservice brakes by using the truck'sauxiliary brakes.

You can also use the "Brake Blending"function for controlled braking. "BrakeBlending" assists the auxiliary brakeswhile you are braking.

Rolling ResistanceRolling resistance plays a major role inyour fuel consumption. It is important touse correctly adapted tires with proper

tire pressure. Check the tire pressure atevery refueling. Incorrect tire pressureresults in increased tire wear andincreased fuel consumption. Check thewheel axle settings on a regular basis ata Mack Trucks dealership.


DRIVING TIPS

DRIVING IN HILLY TERRAIN

• Accelerate in uphill gradients• Let the truck coast when the terrain allows it


DRIVING TIPS

DRIVING IN HILLY TERRAIN

Driving in Hilly TerrainYour driving technique in hilly terrain canmake a major difference to fuelconsumption.

UphillWhen approaching an uphill incline youshould try to maintain your speed andallow the engine to use the truck'spulling power at low revs to get you upthe hill. Release the accelerator pedaljust before you reach the summit andcoast over it. When you change gear, tryto drive according to the tachometerinstead of by engine noise.

DownhillOn downhill inclines you should try toavoid accelerating, and instead allow thetruck to increase speed by coasting.Regulate the downhill speed with thetruck's auxiliary brakes. Make it a habitto completely remove your foot from theaccelerator pedal while you arecoasting. Use cruise control sparingly inhilly terrain as excessive use may resultin increased fuel consumption.

Automatic TransmissionYou can use the truck's "Kick-down"function in order to obtain maximumengine power for driving on a steep hillfor example. This will give you anautomatic downshift.


DRIVING TIPS

DRIVING ON A WINTRY ROAD

• Keep the windshield clear• Make sure you have good visibility• Adapt your speed• Use snow chains or similar


DRIVING TIPS

DRIVING ON A WINTRY ROAD

Driving on Wintery RoadSurfacesWhen driving on wintery road surfaces,there are several functions available foryou to use.

Climate SystemIf there is mist or ice on the windowsthen you can use the defroster functionto clear the windows. In snow flurries forexample, you should set air distributionto just the floor in order to avoid meltingthe snow on the windshield which thenfreezes in a headwind.


DRIVING TIPS

DRIVING IN A DUSTY AND SMOKY ENVIRONMENT

• Use recirculation


DRIVING TIPS

DRIVING IN A DUSTY AND SMOKY ENVIRONMENT

Driving in a Dusty andSmoky EnvironmentYou can use air recirculation in the cabin order to keep out dust and otherunsuitable air. Only use recirculation forshort periods. Clean the inside of thewindshield with normal window cleaningagent on a regular basis.

You can use air recirculation in the cabin order to keep out dust and otherunsuitable air. Only use recirculation forshort periods. Clean the inside of thewindshield with a normal windowcleaning agent on a regular basis.


DRIVING TIPS

DRIVING IN THE RAIN

• Make sure you have good visibility• Adapt your speed• Check the tread depth of the tires


DRIVING TIPS

DRIVING IN THE RAIN

Driving in the RainWhen driving in rain it is important thatyou have good visibility and maintain asuitable speed. If your truck is equippedwith air conditioning then you can use itto remove moisture from the cab. If youneed to remove ice from the windowsthen you can use the defroster.

HydroplaningThe best way to avoid hydroplaning isto:

• Have good tread depth on the tires

• Reduce your speed


DRIVING TIPS

PARKING

• Use the Parking Brake• Avoid use of Idling Speed


DRIVING TIPS

PARKING

ParkingWhen you stop to park there are severalthings you should think about:

Avoid IdlingThe truck does not need to run at idlingspeed before driving off. Warm up theengine at low engine speeds. Avoididling during normal driving as well.Idling normally accounts for 5-6% oftotal fuel consumption, of which 50-80%is unnecessary idling.

Hard DrivingAfter a lot of hard driving you shouldallow the engine to run at idling speedfor several minutes while stationarybefore switching it off in order to reduceexhaust temperature.

DEF FluidWhen driving in colder climates 0 °C(32 °F), idle for at least 90 secondsbefore turning the vehicle off. This willensure that all DEF Fluid has exited thesystem.

Hot TiresTires may become hot after driving longdistances. This can create a hazardwhen parking on inclines in winteryconditions if the tires melt the surfaceunderneath to form ice, leading a vehicleto slide. To avoid, park on a level roadsurface under wintery conditions.


DRIVING TIPS

SERVICE AND MAINTENANCE

• Use the correct fuel for your truck• Follow the service schedule for your truck


DRIVING TIPS

SERVICE AND MAINTENANCE

Service and MaintenanceYou can reduce costs and extend the lifeof your vehicle by performing regularmaintenance. Always use the fuel andoils recommended by Mack Trucks.

Ask your Mack Trucks dealership toassist by providing a customized serviceschedule for your particular truck.

Wheel AlignmentRemember to regularly check the wheeland axle alignment on both tractor andtrailer. Wheel alignment is important forkeeping fuel consumption low andreducing wear on the tires. Tire life canbe extended by avoiding uneven loadsor loads that exceed capacity.

Air SystemTo keep the vehicle's Air Systemworking properly, periodically drain theprimary tank (or one of the circuit tanks).If any water is visible, replace the AirDryer Filter Insert as soon as possible.


DRIVING TIPS

DRIVING ON A SLIPPERY ROAD

• Adapt the speed according to road surface• Use the truck's auxiliary systems on difficult road

surfaces


DRIVING TIPS

DRIVING ON A SLIPPERY ROAD

Driving on a SlipperyRoad SurfaceAlthough your vehicle is equipped withmany traction enhancing features, themost effective action is to adapt yourspeed to the present driving conditions.

Differential LockOn an extremely slippery surface, youcan engage the differential lock so thatthe wheels drive at the same speed.Drive carefully when you have thedifferential lock engaged. Do not forgetto disengage it when you leave theslippery area. If you drive with thedifferential lock engaged on firm groundyou risk damaging the driven axles andwheels.

Weight Distributed over DriveAxleFor a better grip on slippery roadsurfaces you can temporarily redistributethe weight on the driving axle.


SAFETY

SAFETY

SEAT BELTS

Seat BeltsRetractable Seat BeltsThe locking retractable seat belt isdesigned to lock (prevent belt travel outof the retractor) only during suddenstops or impacts. This feature allows theoperator to move freely under normalconditions.

Seat belts cannot be locked by jerkingon the belt, except during sudden stopsor harsh bumps. For the left-side seatposition, this type of seat uses acombination lap and shoulder belt. Forthe right-side seat position

The belt will relock at about one-inchintervals as it rewinds into the retractor.Be sure to pull enough webbing out ofthe retractor before stopping to insertthe end of the belt into the seat beltbuckle. Once it is buckled, the retractorwill pull up the excess webbing andrelock.

Belt Fastening Steps

1 Pull clip so the belt crosses yourshoulder and lap and insert it into thebuckle until an audible snap is heard.

2 Make sure the clip is securelyfastened into the buckle.

3 To tighten the lap portion of thecombination belt, pull upward on theshoulder portion until the lap portion

fits snugly. The belt should rest aslow on your hips as possible.

Belt UnfasteningPush down on the button to release thebelt.

1 Safety Belt

Clean and InspectFor proper seat belt maintenance, seeSeat Belt Maintenance page 208.


LOCKS AND ALARM

LOCKS AND ALARM

LOCKS AND ALARM

DANGERTo lessen the chance of being thrown fromthe vehicle in an accident, always lock thedoors and wear the safety belt whiledriving. Failure to do so can cause seriouspersonal injury or death.

The cab doors can be unlocked andlocked with the same key used for theignition lock. Keys can be made to fitonly one vehicle or all the vehicles in afleet. Insert the key and turn it 1/4 turnclockwise to unlock or counterclockwiseto lock the door.

NOTEThe vehicle is delivered with two identicalkeys. If more keys are needed, order themthrough your authorized Mack Truckdealer.

Locking and UnlockingThe door locks are mechanically orelectronically operated. The lockactivates either from the key on theoutside, or the door lock handle from theinside. With mechanical locks, only onedoor can be locked or unlocked at atime.

Manual LocksWith manual locks, to lock either doorfrom inside the cab, push thedoorhandle inward. The handle stays inplace, indicating the door is locked. Tounlocked without opening the door pullthe handle toward you.

Electronic LocksEach door must be unlocked individuallyfrom inside the cab. To unlock the doorsusing the key, insert the key in eitherdoor look. To unlock, turn the key to the

unlock position (1). To lock, turn the keyto the lock position (2).

1 Unlock (Clockwise)

2 Lock (Counter Clockwise)

Doors

Opening the Cab DoorThe outside door handles are a paddletype design. To open the door, grasp thehandle and pull out while exerting someforce on the door.


LOCKS AND ALARM

LOCKS AND ALARM

To close the door from the inside, placehand in the window track and pull thedoor in.

To close the door from the outside,place hand flat against the door lockarea and push the door shut.

CAUTIONDO NOT shut the door by pushing on thedoor panel. Hard pushing may distort themetal in the door panel.


DRIVINGENVIRONMENT

DRIVING ENVIRONMENT

OVERVIEW OF INSTRUMENTS

Overview of InstrumentsBefore driving this vehicle, locate the instruments and controls, and become thoroughly familiar with their operation. After startingand when driving, ensure that the instrument readings are normal.

Dash Overview


DRIVING ENVIRONMENT


1 Light Control Panel

2 Tachometer

3 Tell-Tale Display

4 Electric Horn

5 Vent

6 Climate Control Panel

7 Switch Locations

8 Brake Pedal

9 Accelerator Pedal

10 Ignition

11 Parking Brake

12 Air Pressure Gauge

13 Fuel Gauge


DRIVING ENVIRONMENT


Gauge Layout

1 Tachometer

2 Warning Indicator Lamps

3 Speedometer

4 Transmission Oil Temperature Gauge

5 Odometer/Trip Counter

6 Voltmeter

7 Engine Oil Pressure Gauge

8 Hour Meter

9 Engine Coolant Temperature Gauge


DRIVING ENVIRONMENT


1 TachometerIndicates engine speed in revolutionsper minute (RPM). Tachometerreadings should be used as a guidefor shifting, as well as to preventengine damage due to overspeed.

2 Warning Indicator LampsIlluminates if a status or faultindicator condition is active.

3 SpeedometerIndicates road speed in miles and/orkilometers per hour.

4 Transmission Oil TemperatureGaugeIndicates transmission oiltemperature.

5 OdometerMeasures the distance traveled bythe truck.

6 VoltmeterIndicates the surface charge of thebattery with the engine NOT running(and the ignition ON). Indicates thecondition of charging system withthe engine running.

7 Engine Oil Pressure GaugeIndicates engine oil pressure. Thenormal operating oil pressure for aMack MP7™ engine (at governedspeed) is

275.8 - 620.5 kPa (40 - 90 psi). Atidling speed, the oil pressure shouldbe 275.8 - 413.9 kPa (40 - 60 psi).Should the oil pressure dropsuddenly from normal readings, stopthe engine immediately anddetermine the cause.

8 Hour MeterIndicates hours of engine operation.Hours of operation should be usedas a guide for certain engine or PTOmaintenance operations.

9 Engine Coolant TemperatureGaugeIndicates the temperature of theengine coolant. The normaloperating temperature for MackMP7™ engines is 77°C - 107°C(170°F - 225°F). The driver willreceive a warning if coolanttemperature reaches 106°C (223°F)and engine shutdown will occur at108°C (227°F) if the engine coolanttemperature shut down option isenabled.

CAUTIONTo avoid component damage, coolanttemperature must NOT exceed 107°C(225°F).

Right Hand Gauges

1 Air Pressure Gauge

2 Fuel/DEF Gauge

1 Air Pressure GaugeIndicates the air pressure in the airbrake system. The normal operatingair pressure is 759 kPa - 897 kPa(110 psi - 130 psi). If pressure dropsbelow 75 psi (±5 psi), the warningbuzzer and warning light will go on.Determine the cause of failure beforeproceeding.

2 Fuel/DEF GaugeRegisters the fuel and DEF levels inthe supply tank(s).


DRIVING ENVIRONMENT


CAUTIONThe maximum safe oil temperature forMack transmissions is 121°C (250°F) formineral-based oil, or 148°C (300°F) forsynthetic oil. Continued operation with oilabove this temperature will cause rapiddeterioration of the oil's lubricatingproperties and is NOT recommended.

Tell-TalesA tell-tale is a display that indicates theactuation of a device, a correct ordefective condition, or a failure tofunction.The operator should become familiarwith these symbols in order to recognizeand react (if necessary) to the indicatedcondition.

ColorsTo promote visual recognitioninternationally, specific colors for tell-tales have been established. Unlessgovernmental regulations (in the areawhere the vehicle is to be used) orengineering directives specify otherwise,the standard colors are:

• Blue – high-beam headlights/enginemaintenance• Flashing Green – turn signals• Flashing Red – hazard conditioninvolving the safety of personnel• Steady Green – system in operation• Steady Red – warning, immediateaction required• Amber – early warning, such as lowfuel or Anti-Lock Brake System (ABS)malfunction

Display SymbolsAlarm, Check and InformationSymbolsNumber Symbol Meaning1 Malfunction

Indicator Lamp(MIL)

2 Wait To Start

3 ElectronicMalfunctionIndicator

4 Engine ShutdownIndicator

5 AftertreatmentDEF Tank LowLevel Indicator

6 Grade Gripper

7 Anti-Brake SystemIndicator (ABS)

8 Turn SignalIndicator

9 R Reverse

10 N Neutral

11 PTO Power Take Off78

X _Publication_PC29

DRIVING ENVIRONMENT


Number Symbol Meaning12 ATC Indicates ATC

Malfunction13 Low Air Indicates low air

pressure14 High Beam

Indicator

15 Parking Brakeengaged

16 AftertreatmentDPF Regeneration

17 CHECK SCR Check SCRIndicator

18 ENGINEDERATE

Engine DerateIndicator

19 VehicleSpeedLimited

Indicates limits inspeed

20 RH Operation Right HandOperation

21 ForcedNeutral

Indicates vehicleis in forced neutral

22 ChangeEngine Oil

Indicates oilchange is needed

23 Road StabilityAdvantage

24 HEST Indicator

Number Symbol Meaning25 Maintenance Due

Indicator

26 Fuel FilterRestriction

27 Air FilterRestriction

28 Engine Oil Level

29 Check Trans IndicatesTransmissionMalfunction

30 Regen InProgress

Regeneration

31 AftertreatmentDPF Regeneration

32 Low Coolant LevelIndicator


DRIVING ENVIRONMENT


Warning Indicator LightPanel

1 Malfunction Indicator lampMalfunction Indicator LAMP (MIL)indicates On Board Diagnostics(OBD) faults. Lamp remains activeafter repair until system operationconfirms repair.

2 Wait to StartIndicates that the intake pre-heat isenabled. Wait to start engine untillight goes out.

3 Electronic MalfunctionIndicatorIlluminates when an electronicmalfunction is detected.

4 Engine Shutdown IndicatorIndicates the occurrence of acondition which requires that theengine be shut down (i.e., low waterlevel, low oil pressure or high watertemperature). If the engine shutdownfeature is enabled, the operator hasabout 15 seconds after the lightgoes on to pull to the side of theroad before the engine shuts off. Ifthe engine shutdown feature isdisabled, the indicator will functionas a warning light but the engine willnot shut down.

5 Aftertreatment DEF Tank LowIndicatorIlluminates when the fluid level islow. It also Flashes when the levelbecomes critically low.

6 Grade GripperGrade Gripper provides anti-roll backassistance during the transition froma stopped position to starting on agrade.

7 Anti-Lock Brake SystemIndicatorIndicates an ABS malfunction. Alsoilluminates momentarily as a bulbcheck when the ignition is turned on.If the light turns on and stays on, amalfunction is indicated. If the lightdoes not turn on when the ignition isturned on, the bulb or (and/or) thepower source may be defective.

NOTEWhen an ABS malfunction is detected,anti-lock braking in the affected wheel willbe disabled and normal braking will return;the other wheels will retain anti-lockbraking.

8 Turn Signal IndicatorsFlashes when the turn signals areactivated.

9 Reverse IndicatorIndicates that the transmission is inReverse.

10 Neutral IndicatorIndicates that the transmission is inNeutral.

11 Power Take-OffIndicates PTO.

12 Automatic Traction Control(ATC) IndicatorIndicates that ATC is operating.

13 Low Air Pressure WarningIndicatorIndicates low air pressure in the airbrake system(s). This feature mayalso come with a buzzer.

14 High Beam IndicatorIndicates that high beams are on.

15 Parking Brake IndicatorIndicates that the parking brake isengaged.

16 Aftertreatment DPFRegeneration Required IconFlashes when the Diesel ParticulateFilter is becoming full/overfull andregeneration is needed.

17 Check SCRIlluminated if a DPF Quality orTampering fault code is active.


DRIVING ENVIRONMENT


18 Engine DerateIlluminate when the engine is in lightor heavy DPF/DEF inducement or ifderate >20%.

19 Vehicle Speed LimitedIlluminate if speed limited via theDEF 5 mph inducement or DPF VSLfunction.

20 Right- Hand OperationIndicates that a right-hand drivemode has been enabled.

21 Forced NeutralIlluminates when PTO is engagedand the truck is not moving.

22 Change Engine OilIf illuminated, immediately check thelevel of your engine oil.

23 The Road Stability Advantage (RSA)telltale blinks whenever the system isactive. The telltale is constantly lit ifthere is a system error.

24 HEST IndicatorThe High Exhaust Temperature(HEST) indicator is displayed whenthe exhaust temperature reaches300°C (572°F) and the regenerationprocess begins. When theregeneration process is completed,the engine should be allowed to rununtil the HEST indicator shuts off.

During regeneration while the vehicleis moving, the HEST indicator willonly illuminate when vehicle speed isless than 8 kph (5 mph). During aparked regeneration, the HESTindicator will turn off whenregeneration is complete and theexhaust temperature has returned toa normal temperature.

25 Maintenance Due IndicatorIndicates that a maintenance alerthas been issued (maintenance isdue).

26 Fuel Filter RestrictionIlluminates when fuel filter conditionreached.

27 Air Filter RestrictionIlluminates when air filter limit isreached.

28 Engine Oil LevelIf illuminated, immediately check thelevel of your engine oil.

29 Check TransIndicates transmission malfunction.Only present on vehicles equippedwith automatic transmission.

30 Regen In ProgressIndicates regeneration is in progress.

31 Aftertreatment DPFRegeneration Required IconIlluminates when the inhibit switch isturned on. It will allow the driver toknow that the switch is in a inhibitposition and a regeneration will notoccur.

32 Low Coolant Level IndicatorIlluminates when the coolant level inthe coolant surge tank is below thespecified level. Stop and addcoolant.


DRIVING ENVIRONMENT


Parking BrakeYellow diamond-shaped knob. Pull toapply. Push to release. Applies theparking brakes.

NOTEThe parking brake DRL allows the daytimerunning lights to be off while the concretepumper is in operation.


DRIVING ENVIRONMENT

CLIMATE CONTROL SYSTEM

Climate Control System

1 Blower Control Knob

2 Mode Knob

3 Temperature Control Knob

4 A/C ON/OFF Button

5 Fresh/Recirculation Button

1. Blower Control Knob — Controls theamount of air delivered through thevents. For desired fan speed, move leverfrom OFF (far left) to HIGH (far right).

2. Mode Selection Knob — Allows theoperator to choose the air direction.

• Foot Position delivers air to the flooroutlets.

• Defrost Position directs air to thewindshield for defogging and/ordefrosting.

• Face Position delivers air to thevents on the dash panel for theupper body.

3. Temperature Control Knob —Controls the temperature of air fromCOOL (far left) to HOT (far right).

4. Air Conditioner On/Off Button —Activates the air conditioning system.5. Fresh/Recirculation Button — Thisbutton lets the operator choose betweenfresh air (from the outside) andrecirculated air (within the cab).

CAUTIONThe air conditioner unit should be run forFIVE MINUTES at least ONCE A WEEKthroughout the year to keep the movingparts well lubricated.


DRIVING ENVIRONMENT

CAB TILT

Cab Tilt OperationDANGER

Before attempting to tilt the cab, becertain to take the following steps:

• Park on a level surface.

• Apply the parking brake.

• Place the transmission in NEUTRAL.

• Shut off the engine.

• Secure all lose items within the cab.

• Close the cab doors.

• Ensure there is enough room to safelytilt the cab.

The cab is mounted on the chassisframe by two front hinges and two rearcab locks. This arrangement allows thecab to tilt forward to a maximum of 60degrees, exposing the enginecompartment for easy accessibility.

The cab tilt system uses one hydrauliccylinder. It incorporates internal safetyvalves which lock up automatically if thecab moves too rapidly in either direction.

The hydraulic fluid pressure imbalanceforces the check valves to seat, holdingthe cab in a hydraulically lockedposition. If this situation occurs,operate the pump in the oppositedirection to open the check valves. Thesystem will then be returned to normaloperation.

Tilting the CabUse the following instructions to tilt thecab:

NOTEBefore raising the cab, the engine must beshut off and all loose items in the cabmust be secured.

1 Take the cab tilt pump handle fromits stored position.

NOTEThe cab tilt pump handle is stored eitherbehind the folding seat or beside the rightside seat on the outer wall of the cab.

2 Insert the handle into the pump andmove the pump control lever to theRAISE position.

1 Pump Control Lever

3 To raise to the service position,pump the cab up to the SERVICEHEIGHT position.

1 Safety Prop

2 Thumb Screw

NOTEIn the service position, the cab must besecured with the safety prop.

4 To secure the cab in the serviceposition, loosen the thumbscrew andswing the safety prop down onto thesafety prop stud. The slot in thesafety prop should settle securelyaround the stud.

WARNINGBe certain that there are no people, toolsor unsecured vehicle parts in the path ofthe descending cab before shifting thepump control lever.


DRIVING ENVIRONMENT

CAB TILT

5 It may be necessary to manipulatethe pump control lever, while the cabis descending, so the safety propsettles on the stud.

6 To raise the cab to the full tiltposition, pump the cab up past thebalance point. Note that the cab willdescend by itself, although the rateof descent may be controlled bymanipulating the pump control leverfrom the RAISE to LOWER position.

Lowering the Cab

NOTEBefore lowering the cab, the cab safetyprop must be in the stored position andthe transmission must be in NEUTRAL.

1 Move the pump control lever to theLOWER position.

2 Pump until the cab is past thebalance point and allow the cab todescend and latch.

3 Leave the pump control lever in thelower position while vehicle is inoperation.


Cab Tilt Operation (AirAssist) if Equipped

DANGERBefore working on a vehicle, set theparking brakes, place the transmission inneutral, and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause seriouspersonal injury or death.

CAUTIONSecure all loose material within the cabbefore tilting.

The cab is mounted on the chassisframe by two front hinges and two rearcab locks. This arrangement allows thecab to tilt forward to a maximum of 60degrees, exposing the enginecompartment for easy accessibility.

The cab tilt system uses one hydrauliccylinder. It incorporates internal safetyvalves which lock up automatically if thecab moves too rapidly in either direction.

The hydraulic fluid pressure imbalanceforces the check valves to seat, holdingthe cab in a hydraulically lockedposition. If this situation occurs,operate the pump in the oppositedirection to open the check valves. Thesystem will then be returned to normaloperation.


DRIVING ENVIRONMENT

CAB TILT

Tilting the CabUse the following instructions to tilt thecab:

NOTEBefore raising the cab, the engine must beshut off and ensure there is enough roomto safelytilt the cab.

1 Move the pump control lever to theRAISE position.


2 Push the button (Air Assist) to raisethe cab up to the Service Heightposition.

1 Air Assist Button

3 Attach the air line to the valve if notenough air is in system to raise thecab.

1 Air Hose

4 To secure the cab in the serviceposition, loosen the thumbscrew andswing the safety prop down onto thesafety prop stud. The slot in thesafety prop should settle securelyaround the stud.

1 Safety Prop

2 Thumb Screw

NOTEIn the service position, the cab must besecured with the safety prop.

5 It may be necessary to manipulatethe pump control lever, while the cabis descending, so the safety propsettles on the stud.

6 To raise the cab to the full tiltposition, pump the cab up past thebalance point. Note that the cab willdescend by itself, although the rateof descent may be controlled by


DRIVING ENVIRONMENT

CAB TILT

manipulating the pump control leverfrom the RAISE to LOWER position. Lowering the Cab

WARNINGBe certain that there are no people, toolsor unsecured vehicle parts in the path ofthe descending cab before shifting thepump control lever.

NOTEBefore lowering the cab, the cab safetyprop must be in the stored position andthe transmission must be in NEUTRAL.

1 Move the pump control lever to theLOWER position.


2 Pump until the cab is past thebalance point and allow the cab todescend and latch.

1 Air Assist Button


DRIVING ENVIRONMENT

CAB TILT

3 Leave the pump control lever in thelower position while vehicle is inoperation.



DRIVING ENVIRONMENT

LIGHT CONTROL PANEL

Light Control PanelThe light control panel is located on thedriver side of the dash. This panelcontrols the parking lights, interior panellights, headlights and fog lights (ifequipped).

1 Light Control Knob/Pull for Fog2 Panel Dimmer Switch3 Dome Lamps

All lights are off when the light controlknob is in the left position. With theknob in the middle position, the parkinglights and interior panel lights willilluminate and with the knob in the farright position, the headlights will turn on.

If equipped, to turn on the fog lights, putthe knob in the far right position and pullout the fog light button. The fog lightsymbol will illuminate indicating thelights are on.

To adjust the intensity of the panel light,roll the panel dimmer switch (2) up anddown.

To turn on the dome lamps, push theright switch up. To turn the dome lampsoff, push the switch down.


DRIVING ENVIRONMENT

STEERING COLUMN

Steering Column

Electrical Switch

1 Turn Signal Lever/ Hazard Switch

Turn Signal Lever

NOTEThe turn signals are not self-canceling andmust be returned to the middle positionmanually.

The turn signal lever is located on thesteering column. It performs a numberof functions, including activating thehigh and low beams and the hazardswitch.

1 Handle in Right Turn Position andCancel Position of Hazard Warning

2 Handle in Left Turn Position andCancel Position of Hazard Warning

3 Pull for Warning Hazard Position

4 Push Button for Hi/Lo Beam


DRIVING ENVIRONMENT

SEATS

Seat AdjustmentVehicles can be equipped with severaldifferent seats. The different seats havesimilar functionality. This sectiondescribes some of the mechanisms thatmay be found on your vehicle's seat.

1 Lubmar Adjustment Knob

2 Seat Back Adjustment Lever

3 Optional Air Lumbar Adjustment Button(Upper and Lower)

4 Weight and Height Adjustment Button

5 Seat Cushion Tilt Adjustment Knob

6 Fore / Aft Adjustment Lever

Lumbar AdjustmentRotate the knob (1) forward to increaseor rearward to decrease the support inthe lumbar area

Seat Back Adjustment1. Lean forward slightly to remove yourweight from the seat back.

2. Pull the seat back angle adjustmentlever (2) rearward to release.

3. Adjust the seat back to the desiredposition within range of adjustment, thenrelease the handle to lock the seat backinto place.

Air Lumbar Adjustment Button1. To increase lumbar support, pressbutton (3) forward.

2. To decrease lumbar support, pressbutton (3) rearward.

Weight and Height AdjustmentButton1. To raise the seat, push the air valvebutton (4) upwards.

2. To lower the seat, push the air valvebutton (4) downwards.

When adjusted properly and undernormal driving conditions, the seatshould not top or bottom against theend limits of the vertical travel. Adjustedheight position should aid the driver'svisibility and vehicle control.

Seat Cushion Tilt AdjustmentKnobRotate the seat tilt knob (5) to decreaseor increase seat tilt.

Fore/Aft Adjustment Lever1. 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 theseat position. (Isolation of the seat isprovided when the lever is in the center[straight] position.)

WARNINGDo not adjust the driver's seat while thevehicle is moving. After adjusting the seatand before driving off, ensure that the seatis firmly latched in position.

WARNINGDo not drive or ride with the seat reclined.In case of a sudden stop, a person in areclined position may slide under the seatbelt.


DRIVING ENVIRONMENT

SEATS

Vehicle Operation From Left-Hand Side When AlsoConfigured With Right-HandStand Up PositionWhen the vehicle is operated from theleft-hand side, and it is desired totransport a passenger on the right-handside, the folding seat’s lower cushionmust be moved to its horizontal positionin order to provide a seating position forthe passenger.

DANGERTo avoid possible severe injury or death,when the vehicle is being operated fromthe left-hand side, a passenger on theright-hand side should sit in the seat, NOTstand.


DRIVING ENVIRONMENT

MISCELLANEOUS CAB EQUIPMENT

Dome Light

1

1 Dome Light

There are four dome lights locatedabove the driver and passenger seat.The overhead dome lamp switch locatedon the dash controls the dome lights.

Air Horn

1 Air Horn

The air horn is activated by pulling downon the cord that is located above thedriver near the overhead console.

Fresh Air Vent

1 Fresh Air Vent

An air vent is provided to circulateoutside air to the cab interior. Move thevent wheel up to open the vent. Movethe wheel to the bottom to close thevent.


DRIVING ENVIRONMENT

MISCELLANEOUS CAB EQUIPMENT

Accessory Power OutletsAdditional 12-volt accessory poweroutlets are located next to the driver onthe panel. These outlets supply 12 voltsof fused power when the ignition switchis turned to the ignition or accessoryposition.

1 Accessory Power Outlets

CAUTIONMaximum amperage for all powerreceptacles in cab is 10 amps. Do NOTexceed maximum amperage asequipment damage may result.

Microphone

1 Microphone

The microphone is located above thedriver next to the radio. The microphonetransmits sound to the phone via BlueTooth.


DRIVING ENVIRONMENT

MIRROR SYSTEMS

Moto Mirror SystemThe mirror system is designed so that:

• Appropriate mirror views are availablefrom both operating positions.

The mirrors of the Moto Mirror Systemcan be adjusted at any time (from insidethe cab) using the adjustment switcheslocated on the center instrument panel.

NOTEThe operator must readjust the mirrorswhen changing between left- and right-operating positions.

Positioning the MirrorsThere are 2 different styles of mirrormounting arrangements available.

On the first arrangement, the left handmirror is mounted on the door and theright hand mirror is mounted on thedoor. Mirrors are positioned in such away so as to be viewed through the doorwindows. The mirrors must bereadjusted when changing positions asshown in the following illustrations:

1 Forward

2 Wipers Must Park at the "Inboard" position

3 LH Driving Position

1 Forward

2 Wipers Must Park at the "Inboard" Position

3 RH Driving Position

1 Forward

2 Wipers Must Part at the "Inboard" Position

3 LH Driving Position

1 Forward

2 Wipers Must Park at the "Inboard" Position

3 RH Driving Position


STARTING ANDDRIVING


POWER SUPPLY

Combination Starter andElectrical Switch

1 Ignition Switch, Engine Start



FUEL TANK CAP

Fuel Tank CapUse Mack approved non-vented caponly or tank damage and/or poor engineperformance may result. DO NOT fill tomore than 95% of liquid capacity.

Diesel Exhaust Fluid (DEF)For information on filling or using DEFFluid, please refer to the DEF section ofthis manual.



FUELING

DANGERDO NOT carry extra fuel containers in thecab. Fuel containers, full or empty, mayleak, explode or give added fuel to a fire.Failure to follow this precaution may leadto serious personal injury or death.

DANGERDO NOT smoke while fueling the vehicle.The glow from the cigar/cigarette canignite the diesel fuel, causing an explosionresulting in serious personal injury ordeath.

DANGERDo not remove the fuel tank cap near anopen flame. Diesel fuel vapors arecombustible and can cause an explosionor fire, resulting in severe personal injuryor death.

CAUTIONDiesel-powered engines for heavy-dutytrucks built on or after January 1, 2010 aredesigned to operate only with Ultra LowSulfur Diesel (ULSD) fuel. Improper fueluse will reduce the efficiency anddurability of engines, permanently damageadvanced emissions control systems,reduce fuel economy and possibly preventthe vehicles from running at all.Manufacturer warranties will be voided byimproper fuel use. Additionally, burningLow Sulfur Diesel fuel (instead of ULSDfuel) in 2007 and later model year diesel-powered cars, trucks and buses is illegaland punishable with civil penalties.

Air is always present inside the fueltanks, entering mainly through the tankventilation. With the air being heatedand cooled, condensation is formed andwater is mixed in the fuel. To avoidcondensation when the vehicle is parkedfor longer periods, fill the tanks up to95% of capacity. Do not fill more thanthat, as the fuel needs to have room forexpansion during the heat of the day.



USE OF BIODIESEL

Mack engines are certified to complywith U.S. EPA and California emissionsstandards based upon the use of testfuels with specifications established bythese regulatory agencies. Alternativefuels, including biodiesel, that are notsubstantially similar to the required testfuels may adversely affect engineemissions compliance and may impactthe performance of certain emissionsaftertreatment components. As a result,Mack does not warrant the engine willconform to applicable Federal orCalifornia emissions limits whenoperated on, or having been operatedon, biodiesel or other alternative fuelsthat are not substantially similar tospecified test fuels used for certification.

The use of biodiesel up to a maximum of10% (B10) in and of itself, will not affectthe manufacturer's mechanical warrantyas to engine or emissions system,provided the bio fuel used in the blendconforms to ASTM D6751, and B1 to B5blends conform to ASTM D975, and B6to B10 blends conform to ASTM D7467.

Customers will need to utilize oilsampling to establish appropriate draininterval(s) for their application(s).



STARTING THE VEHICLE

General Information

CAUTIONDo not engage the starting motor toosoon after an incomplete start of theengine, or the starter can be damaged.Wait at least five seconds beforeattempting to restart the engine.

CAUTIONIf the engine does not start immediately,limit cranking periods to 30 seconds toavoid overheating and damaging thestarter.

NOTEDo not rev the engine at start-up.Turbocharger damage can result becauselubricants need time to establish a filmbetween moving parts.

Before putting the key in the ignitionswitch, set the parking (spring) brake,disengage the clutch (if equipped) andput the transmission in NEUTRAL.

Starting MP Engines1 Crank the engine until it starts.

CAUTIONDO NOT crank the engine for more than30 seconds at a time; wait two minutesafter each try to allow the starter to cool.Failure to follow these instructions couldcause starter damage.

NOTEDo NOT apply the throttle pedal duringengine cranking.

2 After the engine has started, warmthe engine until the coolanttemperature reaches normaloperating range 77–107°C (170–225°F). Once the engine reaches thistemperature, it can be operated in anormal fashion.

NOTELow Idle speed is sufficient for warmingup the engine. Make sure that the parkingbrake is engaged during warm-up. Thisreduces the warm-up time for the engineby allowing an engine warm up process tobe performed correctly.

NOTEYou may notice a change in engine noteduring this process.

NOTEFor bobtail or unloaded applications, theengine can be warmed up by moving thevehicle with "light" throttle applicationafter only one minute of idle.

Priming the MP Fuel System

1 DANGERBefore working on or inspecting a vehicle,set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result inunexpected vehicle movement and cancause serious personal injury or death.

DANGERTo avoid potential fire hazard, do notservice any part of the fuel system whilesmoking or near flames, sparks or hotsurfaces. Also, do not service the enginewhen working on an operating engine.Failure to follow these precautions canresult in fire. To guard against burns fromhot fuel contact, wear adequate protectiveclothing (face shield, heavy gloves, apron,and so on) when working on a hot engine.




WARNINGDO NOT work near the fan with the enginerunning. The engine fan can engage at anytime without warning. Anyone near the fanwhen it turns on could be seriouslyinjured. Before turning on the ignition, besure that no one is near the fan.

Priming the MP Fuel SystemUnlock the hand primer pump bypushing the pump handle in andturning it counterclockwise.

2 Pump the hand primer until the forceof pumping increases.

NOTEWhen the fuel system is empty, 200 ormore pump strokes can be required toproperly prime the system.

NOTEThere are NO bleed nipples to be openedin order to prime the fuel system.

3 Lock the hand primer pump byretracting it into the housing andturning it clockwise.

4 Start the engine and run it at anincreased idle speed forapproximately 5 minutes to removeany remaining air in the system.

5 Check the fuel system for leaks.

NOTEIf the engine does not start following thisprocedure, contact your local certifieddealer.

Engine Warm-Up

CAUTIONIdling the engine unnecessarily for longperiods of time wastes fuel and foulsinjection nozzles. Unburned fuel causescarbon formation and oil dilution. To avoidengine damage, NEVER race an engineduring warm-up.

Engine damage can occur if the engineis not warmed up to a minimumoperating temperature of 77°C (170°F)before operating the vehicle.

Heavy-duty diesel engines are designedto operate at optimum efficiency whenthey are running loaded at normaloperating temperature. This condition iswhere the most efficient combustiontakes place. When the engine isoperated unloaded, lightly loaded (suchas stop-and-go operations, PTOoperations, or periods of extendedengine idling) optimal operatingconditions are inhibited. Also, cold-weather conditions, prevents theachievement and maintaining of normaloperating temperature. As a result,




carbon and/or varnish build-up occursand lubricating oil becomescontaminated with combustion by-products.

Cold-weather operations place addeddemands on a diesel engine. Whenoperating in cold climates (particularly instop-and-go operations, PTO operationsor periods of extended engine idling),maintain minimum operatingtemperature. Otherwise engine damageresulting from valve varnishing andcarbon build-up can occur.

NOTEMany accessories are available for cold-weather operations. Refer to theMaintenance and Lubrication Manual foradditional information concerning cold-weather accessories.

Engine IdlingIdling the engine unnecessarily for longperiods of time wastes fuel, foulsinjector nozzles and can lead to valvecarbon and varnish deposits. Unburnedfuel causes carbon formation and oildilution. Shut down engine whenprolonged loading or unloading of cargois required.

To prevent wear and possible damage tothe engine when it is cold, graduallybring it up to operating temperature

before operating at high engine speedsor full load. Ensure that the Park Brake isengaged, and allow 10 minutes of idletime before departing. Low Idle speed issufficient for warming up the engine, andyou may notice a change in engine note.Operate at partial load until the coolanttemperature reaches 75.

Engine Shut Down

Standard ShutdownAfter a hard run, allow the engine to idlethree minutes before shutdown in orderto stabilize the temperature of all engineparts. Quick shutdowns can causeengine damage and prevent theturbocharger from being properlylubricated.

Shutdown Option: Idle CooldownThis feature provides a means of coolingdown the engine and turbocharger. If theidle cooldown option is enabled and thesystem senses that the turbocharger canbe hot, the engine will not shut down.Specifically this situation occurs whenthe vehicle stops, the parking brake isset, and the key switch is turned to theOFF position. This feature allows thedriver to lock the truck and walk awaywhile still providing adequate cooldown.All switched accessories then turn offonce the engine has stopped. If thisoption is set, the engine can be shut

down immediately by cycling the keyswitch or by pressing the shutdownoverride switch.

The idle cooldown timer is set to 3.5minutes when the engine load exceeds25%. This state occurs if the engine hasbeen running at least 60 seconds. Afterthe load drops below 25%, the timerbegins counting down. If the key switchis turned off before the timer expires, theengine continues to run until the timerreaches zero.

If a pyrometer is installed, the idlecooldown function uses the pyrometerreading to shut down the engine. Thisaction occurs when the temperaturedrops below 232°C (450°F), or after 3.5minutes, whichever comes first.

The default for this option is set at OFFfrom the factory.

NOTEThe parking brake must be set for the idlecooldown function to work.

Engine Shutdown System (IfEnabled)The engine is protected by a system thatprevents engine damage. The systemshuts down the engine whenever apotentially damaging condition (such asloss of oil pressure, loss of coolant orengine overheating) is detected. If the




system detects such a condition, awarning indicator light and an alarmalerts the driver before the engineactually shuts down. Pressing theShutdown Override Switch on theinstrument panel shortly after the vehiclesounds the engine shutdown alarm,allows 30 more seconds of operation.This process can be repeated severaltimes to park the vehicle.

• There is not a time link betweenwhen the warning is activated andwhen the engine shuts down.

• For low oil pressure the engine isforced to idle immediately.

• For Coolant/Oil temperatures, thewarning light can come on and theengine begins to de-rate, but nothingelse occurs unless the temperaturecontinues to rise past the shutdownthreshold. Then the engine is forcedto idle immediately.

• The engine is not shut down until thevehicle speed has dropped below 3kph (2 mph).

• Moving a stationary vehicle to a safearea with an engine protection faultactive. The engine runs forapproximately 30 seconds beforeshutting down again.

CAUTIONContinuously overriding the shutdownsystem can result in severe enginedamage.

Engine Shutdown IndicatorDuring normal operating conditions, thisindicator illuminates when the keyswitch is turned on. After the engine isstarted, it will remain illuminated untilengine oil pressure reaches normal idlingrange. During shutdown, if the systemdetects a condition that could lead toengine failure, the Engine Shutdownindicator illuminates before engineshutdown.

Starting

WARNINGWhen starting the engine, make sure theservice brakes are applied. Failure toapply service brakes may result inunexpected vehicle movement.

No special procedure is required. Thekeypad and strip pushbutton selectorswill automatically initialize in N (Neutral)when the ignition is turned on. Forkeypad pushbutton and bumpshift leverselectors, the Vacuum FluorescentDisplay (VFD) will display “N” for Neutralbetween the SELECT and MONITORlabels. This indicates that Neutral has

been selected and attained, and theengine may now be started. Strippushbutton selectors illuminate a lampin the corner of the N button since theydo not have a VFD.

Cold Weather StartsIf a vehicle is started in cold ambientconditions below 5° C (23° F), thetransmission will be limited to 2nd,Neutral, and Reverse operation until thesump temperature exceeds 1° C (30° F).Once the sump temperature reaches thisthreshold, normal operation will resumefor the transmission.

If the transmission fluid temperature isbelow 10° C (50° F) follow theseprocedures when making directionalshift changes:

• To shift from forward to reverse,select N (Neutral) and then R(Reverse).

• To shift from reverse to forward,select N (Neutral) and then D (Drive)or another forward range.

NOTEDuring cold fluid conditions, always placethe transmission in N (Neutral) prior to anydirection changes.




NOTEFailure to follow these procedures duringcold fluid conditions, may cause theCHECK TRANS light to illuminate and thetransmission to be restricted to N(Neutral).

Preheating

CAUTIONTransmission malfunction or damage mayoccur if you operate the transmission withthe fluid temperature below the minimumfluid temperature specification limit.

CAUTIONThe engine should never be operated formore than 10 seconds at full throttle withthe transmission in range and the outputstalled. Prolonged operation of this typewill cause the transmission fluidtemperature to become excessively highand will cause severe overheat damage tothe transmission.

If ambient temperatures drop below thespecified minimum levels for the fluidtype, preheat the transmission fluidbefore beginning transmissionoperation.

Preheat the transmission fluid using oneof the following methods:

• Use an auxiliary heat source such asa sump heater.

• Operate the transmission in N(Neutral) with the engine running atidle for a minimum of 20 minutesbefore attempting range operation.

Transmission TemperatureThe Allison transmission fluid isminimum temperatures are:

• Fluid Type; TES 295, MinimumTemperature: -35° C (-31° F).

• Fluid Type; TES 389, MinimumTemperature: -25° C (-13 F).

The transmission is consideredoverheated if the temperatures are:

• Sump fluid; 121° C (250° F)

• Fluid to cooler; 149° C (300° F)

• Retarder out fluid; 165° C (330° F)

Typical continuous sump temperature is93° C (200° F).

If the engine temperature gaugeindicates a high temperature, thetransmission is probably overheated.Stop the vehicle and check the coolingsystem. If it appears to be functioningproperly, run the engine at 1200–1500rpm with the transmission in N (Neutral).This should reduce the transmission and

engine temperatures to normal operatinglevels in 2 or 3 minutes.

If the transmission and enginetemperatures do not decrease, reducethe engine rpm. If the enginetemperature indicates a hightemperature, an engine or radiatorproblem is indicated. If high temperaturein either the engine or transmissionpersists, stop the engine and have theoverheating condition investigated bymaintenance personnel.

NOTESome shift schedules may be inhibited asa result of operating conditions, such asengine or transmission fluid temperature.



FUEL ECONOMY DRIVING

GeneralThe absolute fuel consumption (countedin liters per 100 kilometers or miles perUS gallon) is determined by a largenumber of circumstances which can berelated to one of the following mainareas:

• Build specification and equipment

• Service and maintenance

• External environment

• Driving habits

Due to these factors, fuel consumptioncan vary considerably within what iscalled "normal fuel consumption." Fuelconsumption can vary from over 24L/100 Km (10 mpg) when driving emptyon a nice and dry summer road to 67L/100 Km (3.5 mpg) while driving withmaximum permitted GVW, with vehicleand trailer, on a hilly and slushy winterroad.

Build Specification andEquipmentWhenever a vehicle is used fortransportation, its build specification,equipment and gross vehicle weighthave a decisive effect on both fuelconsumption and performance. Thefactors which have the greatestinfluence on fuel consumption areprimarily: driveline combination, heightof trailer or superstructure, use of air

fairings, tire type, number of wheels,gross vehicle weight, and accessories.

Driveline Combination

Engine, transmission and final drivemust be selected in such a way that theengine can operate within the economicspeed range at normal driving speed.This range is defined as where theengine makes the best use of the energycontent of the diesel fuel. A poorlyselected rear axle ratio, which results inthe engine speed being constantlyabove the optimum speed, will increasefuel consumption.

Tires

Heavy duty tires increase rollingresistance considerably. For long haul,choose a smoother, ribbed type tire.Choose a lugged type tire only when theadded traction in mud and snow isneeded.

The number of wheels (axles) has adirect effect on the rolling resistanceand, thereby, the fuel consumption. Forlow volume and/or low weighttransports, use of a 4 x 2 instead of a 6x 4 should be considered.

If the tire pressure is too low, the rollingresistance increases and, thereby,increases the fuel consumption. Theoverall economy is also affected as tirewear increases considerably.

Gross Vehicle Weight

The gross vehicle weight of a vehiclecombination has a large impact on therolling resistance.

Accessories

As a rule, accessories such as roof rack,advertising signs, bug screens, exposedair horns, etc., have a negative effect onfuel consumption.

Service and Maintenance

A modern heavy-duty vehicle requiresregular and preventive maintenance toensure that all its components functionas they should. Use the recommendedpreventive maintenance (PM) programthat has been developed for thevehicles. This ensures optimal energyefficiency from all components that areimportant to fuel consumption.




Brakes

Dragging brakes increase fuelconsumption. They should be checkedregularly. It is important that the releaseaction of the air valves is fast and thatthe moving parts of the wheel brakes arechecked for good adjustment andoperation.

Axles

An axle out of alignment increasesrolling resistance. Regularly check thefront wheel alignment and axles on boththe tractor and trailer/semi-trailer. If theyare correct, there will be less rollingresistance and, therefore, lower fuelconsumption. A good sign of an axle orwheel out of alignment is uneven tirewear.Tires must be checked every time thevehicle is operated as part of the pre-tripinspection.

Engine

Faulty or incorrectly adjusted enginecomponents increase fuel consumption.The list below gives some typicalcomponents that can influence fuelconsumption:

• Blocked (on the outside) charge aircooler/radiator package

• Faulty thermostat

• Blocked fuel filters

• Blocked air intake filter

• Faulty injectors

• Blocked or malfunctioningturbocharger

• Air in fuel system

• Faulty fuel supply pump

• Faulty fan thermostat/clutch

External EnvironmentUnder unfavorable conditions, theexternal environment can have anegative effect on fuel consumption.This can be broken down into two maingroups: weather and wind, and thenature of the roads. Rain, snow, icyconditions and headwinds have a largenegative impact on fuel economy, as dohilly roads and uneven road surfaces.

Headwinds

Headwinds have a large negative impacton fuel consumption. With tailwinds, fuelsaving is only marginal.

Air Temperature

Low ambient temperature contributes toincreased fuel consumption.

Rain, Snow and Road Surface

A wet road surface increases rollingresistance and, thereby, fuelconsumption. Slush will increaseconsumption even more. In certaincases, the surface structure of the road

can also have a negative effect on fuelconsumption.

Gradients

A hilly road with many bends demands ahigher output from the engine. Thedifference between flat, straight roadsand hilly, winding roads can amount toas much as a 50 percent increase in fuelconsumption. When choosing yourroute, avoid hills, rough roads andfrequent stops.




Driving HabitsThe way in which a vehicle is beingdriven is the one factor which has thegreatest influence on fuel consumption.Correct driving saves fuel and reducesvehicle wear. To achieve optimal runningeconomy, the driver should alwaysremember to:

• Start the engine correctly (especiallyimportant in winter season).

• Maintain an even and correct speed.

• Keep the engine at its optimumspeed range.

• Use the correct uphill and downhilldriving technique.

Starting the Engine

Start the engine according to theinstructions in the operator's manual ofthe engine manufacturer. A proper start,especially during the cold season, savesfuel and reduces engine wear. Sluggishlube oil in the engine makes coldstarting more difficult. Therefore, it isimportant to always use engine oil withthe correct viscosity. (For the sake of theoverall fuel economy, it is also importantto have the right viscosity oftransmission and rear axle oils.)

Avoid High Engine Speeds

High engine speeds mean high fuelconsumption. Erratic driving also

increases fuel consumption when thevehicle is constantly accelerated andslowed down. Avoid a higherconsumption by steady, even driving.Refer to each engine manufacturer'soperator's manual for information on theengine's optimum operating range.

Hill Driving Technique

Use the inertia of the vehicle to go overthe crest of a hill under reduced power.Use gravity to help with accelerationwhen going down the hill. Build upspeed before reaching the next uphill.



AXLES

Differential Locks

DANGERDO NOT drive on dry, paved surface withthe differential lock engaged. The vehiclestrives to maintain a straight line. Taking acurve with the differential lock engagedcan cause an accident, leading to seriouspersonal injury or death.

CAUTIONNever operate the vehicle with thedifferentials locked any longer than isnecessary. This state places a great strainon the axles and can cause rapid tirewear.

Under normal traction conditions, do notengage the differential lock. If possible,do not use the differential lock whiletaking a curve. With good traction andthe differential lock engaged, the vehicleis under steered and therefore tends todrive straight in a curve. When using thelock on good traction surface, drivecautiously and do not exceed 40 Km/h(25 mph). Disengage the lock as soon aspossible.

When the differential lock is disengaged,the couplings can be under tension.Disengage the lock by returning theswitch to the OFF position. Help with thedisengagement by briefly letting up on

the accelerator to relieve the torque onthe couplings.

The drive axle can be equipped with thedifferential lock. The single drive axleonly has a wheel differential lock. Withtandem drive axles; there could be bothinterwheel differential lock and aninteraxle differential lock.

Use the differential lock on icy orslippery surfaces. When the slipperysurface is passed, disengage thedifferential lock. The differential lockmust not, under any circumstances, beengaged when in a wheel-spin situation.Engage the lock ahead of the slipperyarea. If already slipping, stop the wheels,engage the lock, and then continue.Engaging the differential lock when thewheels are spinning, damages thedifferential and the rear axle drive unitcould possibly fail.

All efforts must be made to avoidspinning the wheels at high speeds onslippery surfaces. This fact is truewhether the differential lock is engagedor not. Excessive wheel spin can resultin failure of the cluster gears, axle shaftsand other components found within therear axle housing. If unable to obtaintraction, engage the differential lock asdescribed. If still unable to move thetruck, seek assistance from a qualifiedtow operator. Engaging the differentiallocks must always be done as follows:

1 Press the service brakes. Ifnecessary, press the clutch pedal.Wait for the drive wheels to stopspinning.

2 Press the Differential Lock switch.

3 Select a suitable gear for thetransmission.

4 Release the service brakes. Ifnecessary, release the clutch pedal.

CAUTIONDO NOT rely on gauges to determine axlepressure. Weight must be verified onscales. Adjust the air spring pressureaccordingly.

Regulators for adjusting the air springpressure are on the outside of the cab,below the rear corner of the driver sidedoor. Regulators are operated by turningthe knob counterclockwise for loweringpressure, and clockwise for increasingpressure.

CAUTIONThe maximum safe operating oiltemperature for a Mack rear axle is 121°C(250°F) for mineral-based oil, and 148°C(300°F) for synthetic-based oil. Continuedoperation with oil above this temperaturewill result in rapid deterioration of the oil'slubricating properties and is NOTrecommended.



AXLES

NOTEEven when no traction is available at thespinning wheel, the driver can "feather"the brakes (apply the brakes slightly),creating enough resistance at that wheelto allow power to the axle with traction.Feathering brakes should not be donewith power divider lockout engaged.

Engaging the Power DividerLockoutInter-Axle Power Divider Lockout

The Mack power divider can berendered inoperative, during shortperiods of poor traction, using a powerdivider lockout. When the power dividerlockout is engaged, both axles arelocked together (in positive through-drive) for maximum traction with nodifferential action between axles.

It is not necessary to stop the vehicle toengage the power divider lockout.However, the lockout should beengaged while the vehicle is stationaryor is moving at less than 40 Kph (25mph).

CAUTIONTo avoid component damage, do notengage the power divider lockout if thewheels are spinning.

Normally, the Power Divider switch is inthe OUT (disengaged) position. In poortraction conditions, it may be necessaryto provide positive through-drive to bothaxles by flipping the switch to the locked(engaged) position.

1 Push switch to engage.

2 Momentarily release the acceleratorpedal to allow the shift to take place,then drive through the slippery area.

3 When driving conditions permit,unlock the power divider by movingthe Power Divider switch back to theOUT (disengaged) position. Thenrelease the accelerator pedalmomentarily (to shift out of thelocked position) and drive as usual.

CAUTIONDo NOT (under any circumstances)engage or disengage the lockout while thedrive wheels are actually slipping orspinning; clashing between the lockoutsliding clutch and the outer cam mayresult.

NOTEA lockout indicator lamp will remain lit aslong as the lockout is engaged. This is toremind the driver to release the lockout assoon as normal traction is regained.



VEHICLE SPEED RETARDING DEVICES

DANGERWhen operating a tractor bobtail (withouta trailer) or on slippery roads, the enginebrake switch must be in the "OFF"position. Failure to follow this instructioncan result in loss of vehicle control andserious personal injury or death.

NOTEThe vehicle ABS will automatically turn offthe vehicle speed retarding device, IF oneof the sensed rear wheels is locking up asa result of vehicle speed retarding deviceoperation. The vehicle speed retardingdevice will be turned back onautomatically when the wheels becomeunlocked. Consider switching to a lowerbraking level if this occurs frequently.

NOTEIt is normal for there to be a slight delay inthe application of a vehicle speedretarding device. When using devices ofthis type, be sure to think ahead andanalyze conditions in order to use thedevice properly.

A vehicle speed retarding device is notintended to bring the vehicle to a stop. Avehicle speed retarding device is onlyintended to retard the vehicle speedunder certain conditions.



ALLISON TRANSMISSION

List of Warnings

WARNINGUsing the retarder on wet or slipperyroads may cause loss of traction on thedrive wheels—your vehicle may slide outof control. To help avoid injury or propertydamage, turn the retarder enable to OFFwhen driving on wet or slippery roads.

WARNINGTo help avoid injury or property damagecaused by sudden movement of thevehicle, do not make shifts from N(Neutral) to D (Drive) or R (Reverse) whenthe throttle is open. The vehicle may lurchforward or rearward and the transmissioncan be damaged. Avoid this condition bymaking shifts from N (Neutral) to a forwardrange or R (Reverse) only when thethrottle is closed and the service brakesare applied.

DANGERTo help avoid unexpected vehiclemovement that might cause death,serious injury, or property damage, alwayshave your foot on the brake, the throttlereleased, and the engine at idle beforemaking a N (Neutral) to D (Drive); N(Neutral) to R (Reverse); D (Drive) to R(Reverse); or R (Reverse) to D (Drive)selection.

WARNINGIf you let the vehicle coast in N (Neutral),there is no engine braking and you couldlose control. Coasting can also causesevere transmission damage. To helpavoid injury and property damage, do notallow the vehicle to coast in N (Neutral).

CAUTIONWhen starting the engine, make sure theservice brakes are applied. Failure toapply the service brakes can result inunexpected vehicle movement.

NOTED (Drive) may not be attained due to anactive inhibitor. Always apply the servicebrakes when selecting D (Drive) to preventunexpected vehicle movement andbecause a service inhibit may be present.When the selected range is flashing, itindicates the shift to D (Drive) is inhibited.Determine if diagnostic codes are active ifD (Drive) is not attained.

NOTER (Reverse) may not be attained due to anactive inhibitor. Always apply the servicebrakes when selecting R (Reverse) toprevent unexpected vehicle movementand because a service brake inhibit maybe present. When R is flashing, it indicatesthe shift to R (Reverse) is inhibited.Determine if diagnostic codes are active ifR (Reverse) is not attained.

DANGERTo avoid loss of control, use acombination of downshifting, braking, andother retarding devices. Downshifting to alower transmission range increases enginebraking and can help you maintain control.The transmission has a feature to preventautomatic upshifting above the lowerrange selected. However, during downhilloperation, if engine governed speed isexceeded in the lower range, thetransmission will upshift to the next higherrange to prevent engine damage. This willreduce engine braking and could cause aloss of control. Apply the vehicle brakes orother retarding device to preventexceeding engine governed speed in thelower range selected.




DANGERUse of the hydraulic retarder duringinclement weather or when road surfacesare slippery could result in death, seriousinjury, or property damage. On vehicleswhich have a primary retarder controlbased upon closed throttle position, brakepedal position, or brake apply pressure,always manually disable the retardercontrols during inclement weather orslippery road conditions, using the OEMprovided retarder enable switch if present.

DANGERIf the transmission retarder does notapply, death, serious injury, or propertydamage may occur. Operator should beprepared to apply vehicle brakes or otherretarder device if the transmission retarderdoes not apply.

DANGERIf the transmission retarder does notfunction, death, serious injury, or propertydamage may occur. Be sure to test forproper retarder function periodically. If aretarder is present but is not detected by“autodetect,” the retarder will not function.Whenever the retarder does not apply,seek service help immediately.

WARNINGTo avoid personal injury or vehicledamage, do not use the retarder duringinclement weather or when road surfacesare slippery.

DANGERTo avoid personal injury and componentdamange, do not leave the vehicle withthe engine is running. The vehicle canmove unexpectedly and you or otherscould be injured. To leave the enginerunning, do not leave the vehicle until youhave completed all of the followingprocedures:

1 Put the transmission in N (Neutral).

2 Be sure the engine is at low idle (500–800 rpm).

3 Apply the parking brakes andemergency brake and make sure theyare properly engaged.

4 Chock the wheels and take any othersteps necessary to keep the vehiclefrom moving.

WARNINGAvoid contact with the hot fluid or thesump when draining transmission fluid.Direct contact with the hot fluid or the hotsump may result in bodily injury.

NOTEWithout the SAE J1939 communicationdatalink, the shift selector cannot displaythe selected transmission range. Vehicleoperation will be affected.

NOTEAssuming proper installation of directionsignal wire 134, most Allison shiftselectors may still be used to commandtransmission direction changes in thesecircumstances. Due to the failure of theSAE J1939 datalink communication,however, the shift selector cannot displaythe selected range. When this conditionexists, it is advisable to slowly andcarefully apply the throttle each time achange of direction has been selected inorder to verify the direction of operationbefore accelerating the vehicle.

Scope of ManualThis Operator’s Manual contains avariety of information about the Allison3000 and 4000 Product FamiliesTransmission, and its Allison 5thGeneration Controls features.

Additional information about yourtransmission is available atwww.allisontransmission.com using thepublications links shown on the homepage. Refer to the Sales and ServiceLocator at www.allisontransmission.com




to find contact and location informationfor Allison Transmission distributors anddealers.

OverviewSmooth automatic upshifts anddownshifts, without interruption ofpower to the wheels, occur in yourAllison automatic transmission based onengine rpm, throttle position, vehicleload, road speed, and driver or featurerequest, such as manually preselectingranges.

Allison automatic transmissions, alongwith a vehicle specification appropriatefor the particular duty cycle, can providesuperior fuel efficiency and optimum fueleconomy. On trucks with a manual orautomated manual transmission, thepower interrupts that occur during shiftsreduce the engine’s inertia energy,resulting in lower average wheelhorsepower. Because the engine is notworking efficiently, it cannot run at fullload. With an Allison automatictransmission, there is no power interruptduring shift changes. The inertia energybuilt up by the engine is maintained,equating to higher wheel horsepower. Asa result, not as much engine horsepoweris needed to get the job done. Allisonautomatic transmissions providesmooth, seamless shifts at all points ofthe power curve; there is no jarring

power interrupts to jostle the truck,driver or damage valuable cargo. Allisonautomatic transmission equipped trucksare more nimble in traffic and easier tomaneuver in congested loading zones,narrow alleys and around tight corners.You will have fewer freight claims andreduced cycle times, no matter howdifficult the route.

Transmission NameplateThe model number, part number(assembly number), and serial numberare stamped into the transmissionnameplate. These numbers describe thetransmission and all of its components.Use these numbers when orderingreplacement parts or requesting serviceinformation.

1 Allison Nameplate Location

Shifting

1 Reverse Button

2 Neutral Button

3 Drive Button

4 Digital Screen

5 Mode Button

6 Upshift Button

7 Downshift Button




WARNINGTo help avoid unexpected vehiclemovement that might cause death,serious injury, or property damage, alwayshave your foot on the brake, the throttlereleased, and the engine at idle beforemaking a N (Neutral) to D (Drive); N(Neutral) to R (Reverse); D (Drive) to R(Reverse); or R (Reverse) to D (Drive)selection.

NOTEConditions responsible for illuminating theCHECK TRANS indicator will not allowany shift selector changes until the DTCrelated to the condition goes inactive. TheMONITOR display shows the range thetransmission has locked in because of anactive DTC. The SELECT display goesblank when the CHECK TRANS indicatoris on. Move the vehicle to a safe locationbefore turning off the vehicle and seekqualified assistance if needed. Even if thetransmission is not in N (Neutral), theoperator will be able to view DTCs bysimultaneously pressing the ↑ (Upshift)and ↓ (Downshift) arrows, if equipped withthe keypad pushbutton shift selector, orby pressing the DISPLAY MODE/DIAGNOSTIC (DMD) button, if equippedwith the bumpshift lever selector.

With an Allison Transmission, the shiftselector is used by the operator to selectN (Neutral), R (Reverse), or a range offorward gears. When a forward range

has been selected, the transmissionstarts in the lowest gear of the rangeand, as conditions permit, automaticallyupshifts to the highest gear in theselected range.

Shifter Gears• R – REVERSE: selects Reverse gear.

• N – NEUTRAL: selects Neutral. Thearea around the N button is a raisedridge so the driver can identify thepushbuttons by touch, withoutlooking at the display. It is notnecessary to press this button priorto starting the vehicle.

• D – DRIVE: selects the highestavailable forward range. Thetransmission shifts to the startinggear and will automatically upshiftthrough the gears, as operatingconditions permit, until the highestavailable gear is attained.

Upshifting and DownshiftingThe (Upshift) and (Downshift) arrows areused to change the range selected to ahigher or lower forward range:

• One press of the (Downshift) arrowsets range SELECT to the sameforward range as the current forwardrange attained shown in theMONITOR position on the display.

This type of preselect is called anExpress Preselect.

• Each subsequent press of the ↓(Downshift) arrow decreases therange selected by one range.

• One press of the (Upshift) arrowincreases the range selected by onerange.

• If the (Upshift) or (Downshift) arrow isheld continuously, the selected rangewill continue to change up or downuntil the button is released or untilthe highest or lowest possible rangeof gears is selected.

Shift SchedulesEach transmission shift calibrationincludes multiple shift schedules whichare used to control transmission shifts invarious operating conditions. The shiftschedules affect the timing of shiftsbetween gears. The actual number offorward gears is determined based onthe transmission model and the selectedrange position of the shift selector.

Vehicle performance may be affectedwhen shift schedules change. Thetransition between shift schedules canbe initiated by several different actions.

The transmission initially attains firstrange when D (Drive) is selected (exceptfor those units programmed to start in2nd range). As vehicle speed increases,




the transmission automatically upshiftsthrough each range. As the vehicle orequipment slows down, thetransmission automatically downshifts tothe correct range. The SELECT displayshows the highest range available in D(Drive).

NOTEThe vehicle OEM or bodybuilder isresponsible for evaluating the driveabilityof shift schedules in the intended vehicleand duty cycle. For additional detailsregarding these shift schedules and/orother options for primary and secondaryshift schedules, contact a qualified AllisonTransmission service outlet for furtherinformation.

UpshiftingAs long as the Transmission ControlModule (TCM) calculates that there isenough vehicle power and vehicleacceleration available to grant and keepthe next upshift, then there are no otherlimitations imposed on upshifting untilthe vehicle attains its top rangedisplayed in the SELECT display on theselector. Vehicle power and accelerationcharacteristics are monitored by thetransmission controls to attempt toeliminate shift cycling. Shift cycling is anupshift followed closely by a downshift,which is then followed by anotherupshift, and so on.

NOTEIf shift cycling is noted, use the alternateshift schedule by pressing the MODEbutton. The operator can also manuallyselect the next lower range (using the shiftselector) to hold that lower range untilconditions are met to grant the upshiftpoint again without shift cycling.

Hold Schedule for UpshiftsAs a standard feature of each shiftcalibration, the transmission controlsincorporate a "hold upshift" shiftschedule, which the operator may selectif the transmission is not operating in itshighest range. When this schedule isactive, the shift points for upshifts areraised in order to hold the transmissionin its current gear and inhibit upshiftingbeyond the current range. Holds areactivated by selecting the current rangeor a lower range on the shift selector.

CAUTIONA typical use of the "hold" feature is tomaximize engine braking when operatingdownhill. However, in order to preventoverspeeding the engine, the holdfunction is not infinite. It will permit shiftsfrom the hold range to the next higherrange at some speed above the shiftcalibration speed.

DownshiftingDownshifts are allowed to occur as longas transmission output speed is lowenough to keep from overspeeding theengine after completing the downshift.When a range downshift is manuallyselected by the operator, but thetransmission output speed isdetermined to be above the limits, thetransmission remains in the range eventhough a lower range was requested bythe operator. A shift to a lower range canoccur when the operator applies thevehicle service brakes or a retardingdevice, such as an exhaust brake,engine brake, or retarder. This actionreduces the transmission output speedwhich in turn lowers the vehicle speed,allowing the transmission to shift to thelower range.

Preselect Schedule forDownshiftsThe preselect downshift schedule issimilar to the hold feature. The operatormay initiate the preselect downshift shiftschedule by selecting any forward gearon the shift selector that is lower thanthe gear currently in use. When a rangehas been "preselected" in this manner,shifts to and from gears above thepreselected gear range occur at higherthan normal engine speeds. Shifts belowthe preselected range are not affected.Preselect downshifting is beneficial in




maintaining higher engine speed,resulting in increased engine braking orengine brake performance duringdownhill operation or vehicledeceleration cycles. However, preselectshifts are permitted only if an engineoverspeed condition will not occur aftercompletion of the downshift.

NOTEPreselecting during normal operation mayresult in reduced fuel economy.

Performance/Economy ShiftSchedulesCurrently, Allison Transmission offers thefollowing commonly available shiftschedules:

• S1 & S5 Performance: WOT upshiftsnear Full Load Governed Speed(FLGS).

• S2 & S6 Performance: WOT upshiftsat a fixed (less than 100) percent ofFLGS.

• S3 & S7 Economy: Upshifts atspeeds which pull engine down to afixed rpm after the shift.

• S4 & S8 Economy: Upshifts atspeeds which pull engine down to afixed rpm (and less than S3) after theshift.

• S9 Economy: Upshifts anddownshifts occur at speeds that areeven lower than the S4 shift strategy.

• SA Economy: WOT upshifts aresimilar to S1 & S5. The SA part-throttle upshifts and downshiftsoccur at significantly lower speedsthan the S5 part-throttle shifts.

• SB Economy: WOT upshifts anddownshifts similar to SA. The SBpart-throttle upshifts occur at slightlyhigher speeds than the SA part-throttle upshifts.

• SC Economy: WOT upshifts aresimilar to S3 & S7. The SC part-throttle and closed-throttle upshiftsand downshifts are similar to the SApart-throttle and closed-throttleshifts.

• SD Economy: WOT upshifts anddownshifts similar to S3 & S7. TheSD part-throttle and closed-throttleupshifts and downshifts are similarto the SB part-throttle and closed-throttle shifts.

Schedules S1 through S4 are typicallyused with engines using variable speedor all-speed governors. The differencesbetween the schedules is typically closeto full throttle. Schedules S5 through S8are designed to provide the same WOTupshifts as the corresponding S1through S4 schedules. However, the S5

through S8 part throttle shift scheduleshave been modified.

Non-Engine Brake OperationTwo choices of preselect shift schedulesare available for governing preselecteddownshifts during normal transmissionoperation. One of the following choicesis selected when the TransmissionControl Module (TCM) is programmedby the dealer or truck manufacturer:

• Standard Preselects – downshiftsoccur so the engine speed after theshift is approximately 300 rpm abovethe engine governed speed

• Low Preselects – downshifts occurso the engine speed after the shift isapproximately 150 rpm above theengine governed speed

Engine Brake OperationWhen the Transmission Control Module(TCM) detects the engine brake isenabled, it commands use of a preselectshift schedule in order to enhanceengine brake performance. The defaultspeeds for these shifts are known as theAlternate Engine Brake Preselects.

• Alternate Engine Brake Preselects –downshifts occur at engine speedsapproximately midway between1000 rpm and the Standard




Preselects for your transmissionmodel

As an option, the preselect shift pointsduring engine brake operation can bespecified to be the same scheduleselected when the TCM is programmedby the vehicle OEM for non-enginebrake operation:

• Standard Preselects – downshiftsoccur so the engine speed after theshift is approximately 300 rpm abovethe engine governed speed

• Low Preselects – downshifts occurso the engine speed after the shift isapproximately 150 rpm above theengine governed speed

NOTESpecify Standard or Low Preselects whenthe TCM is programmed.

The preselect schedule chosen abovewill be activated for downshifts thatoccur while the engine brake is activeand until operation in a specified gear isreached. This specified gear is theEngine Brake Preselect Range CustomerModifiable Constant (CMC) that isprogrammable using Universal AllisonDOC®. If this CMC is set to a valuehigher than 2nd gear, then downshiftsfrom the Engine Brake Preselect Rangeto 2nd gear will be made as standard

(nonengine brake) closed throttledownshifts. Additionally, if the TCM isprogrammed to make engine brakepreselect downshifts at StandardPreselects or Low Preselects speeds,downshifts between the Engine BrakePreselected Range to an even lowergear can be specified to use theAlternate Engine Brake Preselectdownshift speeds. The lowest gear touse this downshift schedule is also aCMC (Alternate Engine Brake PreselectRange). If this option is specified and theAlternate Engine Brake Preselect RangeCMC is higher than 2nd gear, downshiftsfrom the Alternate Engine BrakePreselect Range to 2nd gear usesnormal (nonpreselect) closed throttleshift speeds.

NOTEIf an exhaust brake or engine compressionbrake is installed on the engine, then theymust be integrated to the transmissioncontrols. Shift quality issues will arise ifnot properly integrated to the transmissioncontrols.

Retarder ModeThe retarder mode shift schedule isautomatically activated when theretarder is switched on in order to raiseclosed throttle downshifts for additionalcooling during retarder operation.

Retarder closed throttle downshiftsoccur at speeds approximately halfwaybetween the normal closed throttledownshift and the preselect downshiftfor each range.

Accelerator ControlThe position of the accelerator pedalinfluences when automatic shiftingoccurs. An electronic throttle positionsignal tells the Transmission ControlModule (TCM) how much the operatorhas pressed the pedal. When the pedalis fully pressed, upshifts occurautomatically at higher engine speeds. Apartially pressed position of the pedalcauses upshifts to occur at lower enginespeeds.

KickdownKickdown is an optional shift schedulewhich is activated when the kickdowninput function is enabled. If shiftschedule S2, S3, or S4 is in use andkickdown is active, all shifts revert toschedule S1, Wide Open Throttle (WOT)shift points. Similarly, if shift scheduleS6, S7, or S8 is in use and kickdown isactive, all shifts revert to schedule S5,WOT shift points.

Avoid transmission performance issuesby contacting an Allison Transmissiondistributor or dealer when one of theseconditions occur:




• A shift quality issue

• A drivability issue such as a vibration

• Transmission, hydraulic line or fittingis leaking fluid

• One of the transmission warningtelltales displays

Transmission Warning TelltalesTransmission OilTemperature

High Transmission OilTemperature

TransmissionMalfunction

Transmission Oil

CAUTIONTransmission damage can result fromextended operation at low fluid levelconditions.

NOTEDo not overfill the transmission.Overheating, oil foaming out of thebreather, and power loss may occur ifdriven while transmission is overfilled.

Only use fluids meeting AllisonTransmission specification TES 295 orTES 389 in the transmission. For a list ofcurrently approved transmission fluids,go to the Allison Transmission web siteat: www.allisontransmission.com, selectSERVICE, Fluids.

Allison Transmission recommends thefollowing into consideration whenselecting the appropriate fluid type foryour transmission:

• Fluids meeting specification TES 295are preferred over TES 389 fluids for usein all 3000 and 4000 Product Familiestransmission applications.

• TES 295 fluids are fully qualified forSevere Duty and Extended Drainintervals.

• A TES 295 fluid allows you to operateat a lower ambient temperature than aTES 389 type fluid. For transmission oiltemperatures refer to TransmissionTemperature section.• A TES 389 fluid is the minimum fluidrequirement approved for use in 3000and 4000 Product Familiestransmissions.

• To extend the TES 389 fluid drainintervals beyond the recommendedmileage or hours change interval, use afluid analysis program.

• When choosing a fluid type to use,consider what the minimum fluidoperating temperature of the fluid will bebased on the ambient temperaturesreached in the geographical location forthe vehicle.

Even though transmission fluid is notconsumed during transmissionoperations engine oil might be, periodicfluid level checks should be made priorto placing the vehicle in service or justafter returning from service. Periodicfluid level checks help preventmechanical failure of a vehicle ortransmission component. Periodicchecks also help to detect fluid leaks,cooler failure (contaminating thetransmission fluid), fluid overfill, fluidunderfill or the wrong kind of fluid usedthe last time the transmission wasserviced.

Check the transmission fluid level usingthe dipstick. The dipstick is marked withtemperature bands for a COLD and HOTfluid level check. The fluid check markedCOLD is designed to allow the fluid levelto be checked from 16° C (61° F) to 60°C (140° F).

There are two temperature bandsmarked on the dipstick to allow for




transmission fluid expansion when thetemperature increases. The lower band,referred to as COLD CHECK, is usedwhen the transmission fluid is belowoperating temperature. The upper band,referred to as HOT CHECK , is usedwhen the transmission fluid is at normaloperating temperature. The OEM mayrefer to these as COLD FULL/COLDADD (COLD CHECK) and HOTFULL/HOT ADD (HOT CHECK).

1 Allison Dipstick, 11 Liter Engine

Cold Check

WARNINGIf you leave the vehicle and the engine isrunning, the vehicle can moveunexpectedly and you or others could beinjured. If you must leave the enginerunning, do not leave the vehicle until youhave completed all of the followingprocedures:

1 Put the transmission in N (Neutral).

2 Be sure the engine is at low idle (500–800 rpm).

3 Apply the parking brakes andemergency brake and make sure theyare properly engaged.

4 Chock the wheels and take any othersteps necessary to keep the vehiclefrom moving.

CAUTIONDO NOT start the engine until thepresence of sufficient transmission fluidhas been confirmed. Remove thetransmission fluid dipstick and be sure thestatic fluid level is near the HOT FULLmark.

CAUTIONThe fluid level rises as fluid temperaturerises. DO NOT fill the transmission abovethe COLD CHECK band if thetransmission fluid is below normaloperating temperatures. During operation,an overfull transmission can becomeoverheated, leading to transmissiondamage.

NOTEWith engine off, the fluid level shouldreach the hot run band or higher on thedipstick even at cold ambienttemperatures. The cold check band iscalibrated on the stick for the fluid levelattained while the transmission is runningand in N (Neutral). Do not move thevehicle until the fluid level reaches thecold full mark with engine running andtransmission in N (Neutral).

NOTEThe correct fluid level cannot bedetermined unless the transmission is in alevel position.

The COLD CHECK band verifies thetransmission has adequate fluid forstartup and operation until it can bechecked at the operating (hot)temperature. Only use this check toconfirm adequate fluid level for a coldstartup and not to set fluid levels for




continued operation. Typically, the checkis most accurate with fluid temperaturesof 16° C (61° F) to 60° C (140° F).

Complete a COLD CHECK procedureusing the dipstick as follows:

1 Move the vehicle to a level surface,put the transmission in N (Neutral)and set the parking brake.

2 With the engine idling (500–800 rpm),shift to D (Drive) and then to R(Reverse) to clear air from thehydraulic circuits.

3 Run the engine at idle (500–800 rpm)in N (Neutral) for about one minute.

4 Clean debris from around the end ofthe fill tube before removing thedipstick.

5 Remove the dipstick and wipe itclean.

6 Insert the dipstick into the fill tube,pushing down until it stops, but stillin its loose or unscrewed position.

7 Remove the dipstick and observethe fluid level. If the fluid on thedipstick is within the COLD CHECKband, the level is satisfactory. If thefluid level is not within this band, addor drain as necessary to bring thelevel within the COLD CHECK band.

8 Perform a HOT CHECK at the firstopportunity after normal operating

temperature (71-93° C (160-199° F))is reached.




Transmission Description:

4000 Product Family;

• Dimension 1: 106.7 mm (4.2 in)

• Dimension 2: 76.2 mm (3 in)

• Dimension 3: 66 mm (2.6 in)

• Dimension 4: *





• Dimension 4: *





• Dimension 4: *

•

NOTE* Dimension determined by installation.

Hot Check

CAUTIONPerform a HOT CHECK at the firstopportunity after normal operatingtemperature

NOTEAlways check fluid level with the dipstickin the unscrewed or loose position.

Hot CheckTo complete a HOT CHECK procedureusing the dipstick, do the following:

1. Be sure fluid has reached normaloperating temperature of 71-93° C(160-200° F). If a transmissiontemperature gauge is not present,measure fluid level when the enginewater temperature gauge has stabilized.

2. Park the vehicle on a level surfaceand shift to N (Neutral).

3. Apply the parking brake and allow theengine to idle (500–800 rpm).

4. Clean debris from around the end ofthe fill tube before removing the dipstick.

5. Remove the dipstick and wipe itclean.6. Insert the dipstick into the fill tube,pushing down until it stops, but still in itsloose or unscrewed position.7. Remove the dipstick and observe thefluid level. The safe operating level isanywhere within the HOT RUN band onthe dipstick.8. If the level is not within the HOT RUNband, add or drain fluid as necessary tobring the level within the HOT RUNband.9. Measure fluid level more than once.Be sure fluid level measurements areconsistent. If readings are notconsistent, be sure the transmissionbreather is clean and not clogged.10. If readings are still not consistent,contact your nearest Allison distributoror dealer.




Oil Change IntervalGeneral Vocation*FluidType

Fluid Change Intervals High Capacity Main*** and Lube FilterChange Intervals

Suction Filter Assembly ChangeInterval

TES295**

Whichever is first of the following:

• 480 000 km (300,000 miles)

• 6000 hours of operation

• 48 calendar months

NOTE: Always replace main and lube filterswith the fluid change***.


• Any time the fluid is changed

• 120 000 km (75,000 miles)



At time of transmission overhaul

TES389**

Whichever is first of following:

• 40 000 km (25,000 miles)



NOTE: Always replace main and lube filterswith the fluid change**



• 40 000 km (25,000 miles)



* General Vocation includes all non-retarder transmissions not identified as severe and intercity coaches with duty cycles of less than onestop per mile.

** A mixture of TES 389 and TES 295 fluid must continue to use the TES 389 schedule shown in this table until two fluid changes with onlyTES 295 fluid have occurred, at which time the TES 295 schedule may be used.

*** This information is based on using Allison Transmission High Capacity filters and a TES 389 or TES 295 fluid type with PrognosticsFeatures not available or turned off.




Severe Vocation*FluidType

Fluid Change Intervals High Capacity Main*** and Lube FilterChange Intervals

Suction Filter Assembly ChangeInterval

TES295**


• 240 000 km (150,000 miles)



NOTE: Always replace main and lube filterswith the fluid change***.



• 120 000 km (75,000 miles)



At time of transmission overhaul

TES389**

Whichever is first of following:

• 20 000 km (12,000 miles)



NOTE: Always replace main and lube filterswith the fluid change**



• 20 000 km (12,000 miles)



* Severe Vocation includes all retarder equipped transmissions, or vocations for On/Off Highway, Refuse, Transit, and Intercity Coach withduty cycle greater than one (1) stop per mile.

** A mixture of TES 389 and TES 295 fluid must continue to use the TES 389 schedule shown in this table until two fluid changes with onlyTES 295 fluid have occurred, at which time the TES 295 schedule may be used.

*** This information is based on using Allison Transmission High Capacity filters and a TES 389 or TES 295 fluid type with PrognosticsFeatures not available or turned off.




Oil and Filter Change

WARNINGAvoid contact with the hot fluid or thesump when draining transmission fluid.Direct contact with the hot fluid or the hotsump may result in bodily injury.

NOTEDo not drain the transmission fluid if onlyfilters are being replaced.

NOTEAt each fluid change, examine the drainedfluid for evidence of dirt or water. A normalamount of condensation appears in thefluid during operation.

Drain Fluid1 Drain the fluid when the transmission

is at operating temperature of 71–93°C (160–200°F). Hot fluid flowsquicker and drains more completely.

2 Remove the drain plug from thecontrol module and allow the fluid todrain into a suitable container.

3 Examine the fluid for contamination.

CAUTIONDo not use the bolts to draw the filtercovers to the control module. Do not usean impact wrench to tighten the bolts.Using an impact wrench to tighten thebolts may cause stripped threads andexpensive parts replacement. Use atorque wrench to tighten the bolts.

Replace Filters1 Remove 12 bolts (6), two filter covers

(5), two gaskets (4), four O-rings (2and 3), and two filters (1) from thebottom of the control module.

2 When reinstalling parts, lubricate andinstall new O-rings (2 and 3) on eachfilter cover (5). Lubricate O-ringinside filter (1) and push filter ontocover (5). Install new gaskets (4) oncover (5) and align holes in gasketswith holes in cover.

3 Install filter and cover assembliesinto the filter compartment. Aligneach filter/cover assembly with theholes in the channel plate/sump.Push the cover assemblies in byhand to seat the seals.

4 Install 12 bolts into filter cover andtighten to 51–61 Nm (38–45 lb ft).

5 Replace the drain plug O-ring. Installthe plug and tighten to 25–32 Nm(18–24 ft-lb).

1 Filter

2 O-ring

3 O-ring

4 Gasket

5 Filter Cover

6 Bolt

7 Lube Filter

8 Main Filter

9 Drain Plug




Transmission Fluid RefillThe fluid refill volume will be less thanthe volume listed for the initial fill due tosome fluid remaining in the externalcircuits as well as in varioustransmission component cavities. Afterrefill, verify the fluid level is correct.

Transmission Fluid CapacitySump Initial Refill Refill

Liters Quarts Liters Quarts

3000 Product Family

4 inch 27 29 18 19

2 inch 25 26 16 17

4000 Product Family

4 inch 48 51 40 42

2 inch 41 43 33 35



ANTI-LOCK BRAKING SYSTEM

WARNINGFor proper ABS operation, DO NOTchange tire sizes. The size of the tiresinstalled during production is programmedinto the electronic control unit. Installingdifferent sized tires could result in areduced brake force, leading to longerstopping distances or accidents.

The vehicle has a standard brakesystem, equipped with an electronicspeed monitoring and control system,Anti-lock Braking System (ABS). ABSmonitors wheel speed continuously butis not involved in controlling the wheelspeed unless there is an emergency. Innormal braking applications, thestandard air brake system is in effect.

There is a sensor installed in each wheelon a monitored axle. The sensorstransmit information to the electroniccontrol unit (ECU). The ECU interpretsthe signals and calculates wheel speed,wheel retarding and a vehicle referencespeed. If the calculations indicate awheel lock-up situation, a signal is sentfrom the ECU to the appropriate ABSmodulator valve to reduce brakingpressure. During emergency braking, themodulator valve alternately reduces,increases or maintains air pressure inthe brake chamber to prevent wheellock-up.

During emergency or reduced-tractionstops, fully depress the foot brake pedaluntil the vehicle comes to a safe stop.DO NOT PUMP the brake pedal. Withthe brake pedal fully depressed, the ABScontrols all wheels to provide steeringcontrol and a reduced braking distance.

Although the ABS improves vehiclecontrol during emergency brakingsituations, the operator still has theresponsibility to change driving stylesdepending on the existing traffic, roadand/or weather conditions. For example,the ABS cannot prevent an accident ifthe driver is speeding or following tooclosely on slippery surfaces.

The ABS control unit contains a self-testing program that is engaged eachtime the ignition is turned on. Theoperator can verify the testing bylistening for the ABS modulator valvesactuating twice in series. To increase thesound, hold down the foot brake pedalwhen the ignition is turned on.

If any of the ABS tell-tales come onduring driving or do not go out after ashort time after turning on the ignition,take the vehicle to an authorized dealerto repair the ABS or brake system. Thevehicle can still be driven with a problemin the ABS system. However, ABS is

disengaged and the standard brakingsystem operates only.

The instrument cluster also contains anABS tell-tale lamp, which indicates whena Trailer ABS system issue occurs.


INFOTAINMENT

INFOTAINMENT

RADIO

IntroductionThe information provided are generalfeatures found for the operation of theDEA5XX Radio.

1 Phone

2 Play/Pause

3 Browse

4 Check/Alarm

5 RPT (Repeat)

6 RDM (Random)

7 ESC (Escape)

8 DSP (Display)

9 Scan/ASCN (Scan/Autoscan)

10 PREV (Previous)

11 Eject

12 Next (Next)

13 SRC/PWR (Source/Power)

14 Knob

Radio Button Operation• SRC/PWR: Press to switch to FM ->

AM -> WX -> SXM -> CD -> USB/iPod -> AUX -> Bluetooth Audio (ifequipped) and to turn Radio ON.Press and hold to turn radio OFF.

• One-Hour Timer: With the ignitionoff, pressing the SRC/PWR buttonwill turn on the receiver and activatethe receiver’s one-hour timer.

• VOLUME KNOB/OK: Press for lessthan 3 seconds to display AudioControl Menu. Press for more than 3seconds to Show the User Menu.Rotate to Increase/decrease Volumeor during a Menu for Navigation.Press while in a Menu to confirm theselection.

• PREV (Previous/Reverse): Press toselect previous track or station.Press and hold for FR or Tune Down

• NEXT (Next/Forward): Press to selectnext track or station. Press and holdfor FF or Tune Up.

• EJECT: Press to eject the CD

• PHONE (If equipped): Press thePhone button for more than 3seconds to Show the BluetoothMenu. When Bluetooth is enabled,press the button to display the DialMenu or to accept and Incoming Call

(if a Phone is paired).During a callPress the button for more than 3seconds to transfer the call from theradio to the Phone.

• CLOCK ALARM: Press during Alarmactivation to cancel the Alarm.

• SCAN/ASCAN: Scans stations/CDtracks/MP3/ WMA files and foldersand stores strongest stations topresets.

• PLAY/PAUSE: Press to pause/unpause current Media.

• RPT (Repeat): Press to repeatcurrent track. Press again to stoprepeat. Look for the RPT icon to turnon in the radio display.

• BROWSE: Press to Navigate on thedevice and select a specific song orplay context (Applicable to USBsticks, CD MP3 discs and iPods)

• RDM (Random): Press to play thetracks randomly. Press again to stoprandom mode. Look for the RDMicon to turn on in the radio display.

• ESC (ESCAPE): Press to exit oneMenu Level.

• DISP (DISPLAY): If vehicle Ignition isON: Press to Change Source DisplayViews. Press for more than 3seconds to show the Clock for ashort time. If vehicle Ignition is OFF:


INFOTAINMENT

RADIO

Press to turn on the Radio and showthe clock for a few seconds.

Radio FeaturesTo access AM, FM, WX, SXM (ifequipped), iPod, USB, Rear Aux, FrontAux, CD or BT Audio do one of thefollowing:

• Press the SRC radio button to scrollthrough the options and select thedesired one.

• Press the SRC button and then scrollthe source menu by knob rotation orNEXT/PREV short presses and thenselect by short-pressing theknob.CD/MP3, USB/iPod, Front AUXand BT Audio shall be accessed onlyif the radio model supports them anda device is connected/inserted forthat specific source.

AM-FM-WX RadioTuning: Select the desired “TunerConfiguration” following the steps in theAudio Controls Menu section.

If is set to MANUAL, the radio will:Execute Manual Tuning when the NEXT/PREV buttons are short pressed andExecute Seek when the NEXT/ PREVbuttons are long pressed. If is set toAUTO, the radio will: Execute Seekwhen the NEXT/PREV buttons are shortpressed and Execute Manual Tuning

when the NEXT/PREV buttons are longpressed.

Manual Tuning: The current frequencywill be increased/decreased by 1 step of0.2MHz (USA FM mode), 10 kHz (USAAM mode) and one channel in WX mode(CH1, CH2. etc.)

Seeking a Station: When the Seekfunction is activated the radioincrements/ decrements the frequencyuntil a tunable station is found. If atunable station is not found the radio willdisplay “NO STATION FOUND”.

Storing Radio Station Presets : Tune thedesired frequency, and then long pressany of the Preset(1-6) buttons until theradio produces a beep.

Tuning Radio Station Presets: Shortpress on any of the Preset(1-6) buttons.

SCAN: To initiate the Scan function,short press the SCAN/ASCN button.When SCAN is initiated, the radio seeksup in frequency and stops on the nextstrong frequency for 8 seconds beforecontinuing to seek for the next strongstation.

AUTOSCAN: This function temporallystores the strongest 6 stations of thecurrent band in the presets until theradio is powered off or the source ischanged. To initiate the AUTOSCANfunction, long press the SCN/ASCNbutton until the radio performs a beep;

then the “AUTO SCAN” icon will blinkwhile the radio is storing the temporarypresets.

SiriusXM®Vehicles with a valid SiriusXM® satelliteradio subscription can receive SiriusXMprogramming.

Display labels: To easily recognize thedisplayed text, the radio uses thefollowing convention: Channel Number:CH, Channel Name: CH, Artist Name:ART, Content Info: INFO, Song Title:SONG, Category name: CAT.

SXM Categories To change the currentcategory long press the NEXT/PREVbutton and the radio will tune the firstchannel on next or previous category.Category mode Enable/DisabledCategory Search Mode Enabled meansthat only channels in the currentCategory are searched. When enabled,the CATEGORY icon is turned on.Category Search Mode Disabled meansthat all channels are searched. Whendisabled, the CATEGORY icon is turnedoff.

SXM Radio ID: If tuned to channel 0,“RADIO ID” label alternates with theSXM radio eight-digit code. This code isneeded to activate the service.


INFOTAINMENT

RADIO

Radio System Settings

Audio Controls Menu

ClockTo adjust the time in the radio, press theknob to show the Audio Control Menu.Rotate the knob until the Clock is shownon the display and press the knob toenter the Clock Menu.

Once in the Clock Menu you can select12 Hour or 24 Hour format by rotatingthe knob and pressing it to confirm.Finally after the format configuration andconfirmation, adjust the time settingsand confirm the changes by pressing theKnob.

AlarmTo set the Alarm press, enter the AudioControl Menu, select Alarm and pressthe knob. Once in the Alarm Menu,change the ALARM ON/OFF by rotatingthe knob and pressing the knob toconfirm the selection. When the userselects ALARM ON, the Alarm Icon willbe set to ON and the followingconfiguration options will be shown:

• TIME: The hour digits for the alarmtime will begin to flash. The formatwill be the same as you set for theclock (12 or 24 hour mode). Changeby rotating the knob and confirm the

hour and minutes by pressing theknob.

• SET TONE or SET MUSIC: Changebetween SET TONE or SET MUSICby rotating the knob and pressingthe knob.

• VOLUME: For Tone change betweenLow, Mid and High. For Music adjustfrom 0 to 30.

• Turning the Alarm Off: When thealarm is triggered, short press thepreset 3 button. If you do not turnthe alarm off, it will automaticallyshut off after 63 minutes.

• Activating Snooze: To use SNOOZE,press any button for less than 2seconds when the alarm sounds,except Preset 3 button. SNOOZE willappear for 3 seconds and the alarmwill be postponed for 9 minutes.

User MenuThe User Menu is shown when theVolume knob is pressed for more than 2seconds. In this menu the user canconfigure the following options:

• Speakers (SPEAKERS)

• Seek Sensitivity (SEEK SEN)

• Tune Configuration (TUNE CFG)

• Playback Configuration (PLBK CFG)

• Dimming (DIMMING)

• Category Enable/Disable (CAT E/D)

• HUE Adjustment (HUE ADJ)

• Speed Dependent Volume(SPEEDDV)

Playback Configuration (PLBK CFG):This option is used to configure theNext/Prev Button for the long pressfunctionality (between FF/FR and FolderUp/ Down).The display will show thecurrent selected option SEEK (folder Up/Down) or FAST F/F. Rotate the knob tochange between SEEK or FAST F/F,press the Knob to select the desiredoption. This option is only availablewhen radio is playing CD, USB or iPodMode.

Category Enable/Disable (CAT/E/D): Thedisplay will show CAT ENABLE or CATDISABLE depending on the currentselection. Rotate the knob to changebetween the two options and press theKnob to confirm the selection. Thisoption is only available in SXM Mode.

Speed Dependent Volume (SPEEDDV):User can select betweenOFF/LOW/MID/HIGH settings. Volumewill be increased accordingly in the radioas vehicle speed increases/decreases.


INFOTAINMENT

RADIO

NOTEThe Regulatory notices are listed in theowner´s manual located in the followingweb site.http://www.panapacific.com/support

Media Players

CD PlayerWith the vehicle on, insert a disc into theslot, label side up. The system iscapable of playing:

Most audio CDs, CD-R and CD-RW.MP3or unprotected WMA formats.

Folder Up/Down (only available whenplaying

MP3 CDs and USB devices) Press toselect next/Previous Folder, if playing aspecific playable scope, when pressingthe radio plays track 1 as newly insertedUSB.

Music Navigation CD MP3 and USBPress the magnifying glass (preset 2)button while CD, MP3 or USB source isactive to access the CD MP3/USBMusic Menu. Use the Volume Knob orNext/Prev button to navigate throughthe different options.

The Radio has two Options

Folder Mode: Press the Volume Knob toview the folders stored on the disc.

Select a folder to view the list of allsongs in that folder.

Playlist Mode Press the Volume Knob toview the playlists stored on the disc.Select a playlist to start playing the firsttrack in current selected playlist.

Special Considerations

Root Directory: The root directory istreated as a folder. All files containeddirectly under the root directory areaccessed prior to any root directoryfolders.

Empty Folders: If a root directory orfolder is empty or contains only folders,the player advances to the next folder inthe file structure that contains acompressed audio file. The emptyfolder(s) are not displayed or numbered.

iPodThis Radio supports the following iPodmodels: iPod classic® (6th generation),iPod nano® (6G), iPod touch® (4G),iPhone® (3G, 3GS, 4, and 4S)

Other iPods may be played, butfunctionality is not guaranteed.

Playing from an iPod

1. Connect one end of the standard iPodUSB cable to the iPod's dock connector.

2. Connect the other end to the USBport in the front radio display (it beginsto play).

3. Radio will start playing the iPod andshows the track number, Song, Artist,elapsed time, and Album informationdisplays when available.

4. The iPod battery rechargesautomatically while the vehicle is on.

5. If the iPod is an unsupported model, itcan still be listened to in the vehicle byconnecting to the auxiliary input jackusing a standard 3.5mm (1/8 in) stereocable.

iPod Menu Press the magnifying glass(preset 2) button while USB source (iPodconnected) is active to access the iPodMusic Menu. Use the Volume Knob orNext/Prev button to navigate throughthe different options.

Use the iPod Audio Menu to select:Playlists, Artists, Albums, Genres,Podcasts, Songs, Composers, AudioBooks.

USBA USB mass storage device can beconnected to the USB port.

The USB port is in the front of the radiodisplay. Five volts DC power is limited toone-amp from this port. Devices such asiPad that require greater current will notcharge from this port.


INFOTAINMENT

RADIO

USB MP3 Player and USB Drives:

The USB MP3 players and USB drivesconnected must comply with the USBMass Storage specification.

Front Auxiliary / Rear AuxiliaryIn front auxiliary mode, you can play anexternal device such as an iPod® or MP3player via the auxiliary input jack on thefront of the receiver. To use an externaldevice simply connect the device via theauxiliary input jack.

In rear auxiliary mode, you can play anexternal device that you have connectedvia the receiver’s rear power auxiliaryinput lines. To use an external devicesimply connect the device via theauxiliary input jack and select it usingthe source button

Bluetooth®The Bluetooth Menu is available whenthe Phone button is pressed for morethan 3 seconds. To navigate through it,rotate the knob. The Bluetooth Menuconsists on the following options:

• BT ENABLE

• CONNECT PH

• DISCONNECT PH

• ADD PHONE

• DELETE PH (Some options are onlyavailable when a device has beenpaired previously)

• Enabling/Disabling Bluetooth: Enterthe BT menu and Rotate the VolumeKnob until the display shows: BTDisable or BT Enable. Press theVolume Knob to Enable or Disablethe Bluetooth.

• Pairing a Bluetooth Device: Enablethe BT in the Radio and your device.Enter the BT Menu and Rotate theVolume Knob until the displayshows: ADD PHONE, press thevolume The radio will displayADDING PH for 3 seconds and theBluetooth status icon will blink. Theradio will be in discoverable mode,set your cell phone to add aBluetooth device and look for thename “Delphi500 Radio.” Follow theinstructions on your phone to add aconnection. When necessary, use 4PIN numbers 0000 to connect to theradio. When the cell phone has beensuccessfully added, the radio willdisplay PH CONNECTED for 3seconds and then the Bluetoothdevice name for 3 seconds. PhoneIcon will be active on the display.

• Connecting a Device: If your devicewas previously paired, you cansimply connect to the device: Go tothe BT Menu and select CONNECT

PH. The radio will attempt theconnection to the selected device.The Phone icon will be active andthe arrows icon will flash. When theradio connects, the Bluetooth iconwill blink. This signifies that thereceiver is attempting to downloadthe cell phone’s CONTACTS (for theDIAL CONTACTS function). The iconwill cease to blink if all contacts havebeen downloaded or if the radiotimes out from receiving contactsfrom the cell phone device. PhoneIcon remains active.

• Disconnecting a Device: If yourdevice is currently connected andyou require disconnecting it from theradio: Go to the BT Menu, selectDISCONNECT PH by pressing theknob, The radio will showDISCONNECT PH for a short time.Once the Phone is disconnected theradio will display DISCONNECTEDfirst and then the Bluetooth devicename. The Phone Icon will beinactive.

• Deleting one or all Devices: To deletefrom the radio one or all devicespreviously paired: Go to the BTMenu, select DELETE PH and pressthe knob. The radio will show adevice list (navigate through it byrotating the knob). Select the deviceto be deleted or select DELETE ALL


INFOTAINMENT

RADIO

to erase all the paired devices in thelist by pressing the Volume Knob.

• Hands Free/ Bluetooth Features:Once your device is properly paired(see pairing a Bluetooth Device) andconnected (See Connecting aDevice), the radio may support thefollowing Hands Free features if theconnected device has that capability.

DIAL MENU

The radio can retrieve the last calls andcontact information from the device. Thedial menu is accessed when the deviceis not in a call and the Phone button ispressed.

• Redial: The user can retrieve the lastnumber called and place a call.Press the Phone button and the lastnumber called will be dialed.

• Quick Dial: The radio is capable ofstoring phone numbers in any of thefive available preset buttons. To savea phone number, you can select thecontact using either the DIALCONTACTS feature or the LASTCALLS feature. When the desiredcontact phone number is displayed,press and hold any of the PRESETbuttons until you hear a beepconfirming the phone number hasbeen saved. To dial a saved phonenumber, select QUICK DIAL from themenu and rotate the knob to select

the appropriate PRESET number.Press the knob to place the call tothe saved phone number.

• Dial Contact: The radio is able toread and display the phone contactsfrom the device. Press the Phonebutton to show the DIAL MENU androtate the knob until DIALCONTACTS is shown, press theknob to select this feature. Rotatethe knob to select between thedifferent stored contacts. Press theOK button if you want to dial to thelisted contact. The radio will attemptto download the following phonenumbers from each contact: HOME,WORK, MOBILE, OTHER andPREFERRED. Within the menu theywill be displayed as either: H, W, M,O or P plus the 10 digit number(XXX-XXX-XXXX).

• Last Calls: The radio is capable oflisting the last 10 calls (DIALED,RECEIVED AND MISSED). Rotatingthe knob will navigate the userthrough the selected call list. Pressthe OK button to place the call.

• Call Options: The following optionsare available during a hands free call:

Accepting a Call: When an incoming callis received, the radio will display thename and number of the caller. To

accept the call, press the OK, NEXT,knob or Phone button.

Rejecting a Call: To reject the call, pressthe ESC or PREV button.

Ending a Call: To end a call, press theESC button.

Microphone Mute: Pressing Pause/Playwill mute the radio’s microphone duringa call. Press again to deactivate mute.

Call Transfer: If a call is in progress,press the Phone button for more than 3seconds to transfer the call to the cellphone for private conversations. Repeatthis process if you want to return intoHands Free mode again.

BT Audio: Bluetooth Player

If your cell phone supports it, it can beused as an audio source input to theradio, allowing you to enjoy the musicfiles stored on your phone. To accessmusic files on your phone press the SRCbutton and select BT AUDIO.

In BT AUDIO you can use the followingbuttons (See Play/Pause, PREV(Previous)/NEXT (Next), FF/FR (FastForward/Fast Reverse) and RDM(Random)/RPT (Repeat).


MAINTENANCE,LUBRICATION AND

SERVICE

MAINTENANCE, LUBRICATION AND SERVICE

PRE-TRIP INSPECTION AND DAILY MAINTENANCE

DANGERBefore working on or inspecting a vehicle,set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result inunexpected vehicle movement and cancause serious personal injury or death.

Safety is the most important andobvious reason for doing a pre-tripinspection. Federal and state lawsrequire inspection performed by thedriver. Federal and state inspectors alsoinspect commercial vehicles. An unsafevehicle can be placed "out of service"until the driver or owner corrects thedeficiency. Owners and operatorsshould familiarize themselves withsections 49 CFR 396.11 and 396.13concerning Federal requirements forvehicle inspection. Certain other lawsmay also apply.

Section 49 CFR 396.13 states that allmotor carrier drivers must complete awritten report at the end of each workday for each vehicle operated, coveringmost of what is covered in the pre-triplist. The report should list all defects ordeficiencies discovered by the driver. Apre-trip inspection prepares for the end-of-work report.

Starting on the next page are suggestedguidelines to be used in performingtruck, tractor and trailer pre-trip

inspections. Depending on theapplication of the vehicle being used,these guidelines should be modified toinclude other necessary inspectionpoints. For example, steps and grabhandles should be checked daily onrefuse trucks because the operator isgetting in and out of the cab morefrequently.

If any component or system does notpass this inspection, it must becorrected before operating the vehicle.Whenever equipment requiresadjustment, replacement, repair orlubrication, refer to the Service Manualsor contact an authorized dealer for thecorrect procedures, specifications andintervals. Take your time going throughthe pre-trip inspection. Remember that acareful pre-trip inspection saves time byeliminating unscheduled stops forcorrecting a faulty item. The followinginformation has been provided by theAmerican Trucking Association asdeveloped by the D.O.T. Office of MotorCarriers (BMCS).



PRE-TRIP INSPECTION QUICK LIST

1 Pre-trip Approach VehicleInspect the vehicle in a circularmanner.

Approaching the Vehicle

• Check under the vehicle for oil,fuel, coolant leaks or other signsof damage.

• Check body surfaces for signs ofbreaks or damage.

Preparation

• Open drain cocks on air tanks tolet the tanks drain.

• Chock wheels on vehicle and, ifhooked up, trailer.

• Close air tank drain cocks.

• Start the engine and let the airpressure build up to normal. Stopengine check for air leaks.

• Switch on parking lights andhazard lights.

• Apply parking brakes. Listen forair leaks.

• Raise cab so belts can bechecked.

2 Left Side of the CabLeft Front Wheel

• Check condition of wheel rim.Especially look for cracks,

missing lockrings, bent or brokenstuds, missing clamps or lugnuts.

• Check condition of tire: properlyinflated, no serious cuts, bulges,tread wear or any signs ofmisalignment; valve stem nottouching wheel, rim or brakedrum; valve cap in place.

• Check wheel bearing and hub:no obvious leaking on outside orinside wheel. Verify correct oillevel in hub.

Left Front Suspension

• Check condition of spring, springhangers, shackles, u-bolts: nocracks, breaks or shifting.

• Check shock absorber condition.

Left Front Brake

• Condition of brake drum. Withbrakes released, look for anoticeable gap between liningand drum. This check cannot bemade if dust covers are in place.

• Condition of brake air hose.

• Check brake chamber mountingbolts and bracket.

• Check slack adjuster andchamber pushrod travel forproper brake adjustment.

Left Front Axle and SteeringSystem• No loose, worn, bent, damaged

or missing parts.

Engine Compartment, LeftSide• Check coolant hose condition.

• Check condition of fan drivebelts.

• Check engine and surroundingareas for coolant, oil and fuelleaks.

• Check wiring harnesses for signsof damage.

3 Front of Cab AreaCondition of Windshield

• Check for damage and clean ifdirty.

• Check windshield wiper arms forproper spring tension.

• Check wiper blades for anydamage, "dead" rubber andattachment to arm.

Lights and Reflectors

• Lower cab and inspect parking,clearance and identification lightson cab. They should be clean,operating and of the proper color.




• Reflectors clean and propercolor.

• Turn on headlights. High and lowbeams should be operating andlenses clean. If equipped, checkdaytime running lights.

• Left and right front turn signallights clean, operating andproper color.

Grille

• Check that charge air cooler andradiator or bugscreens are cleanand undamaged.

4 Right Side of Cab AreaRight Front Wheel

• Check condition of wheel rim.Especially look for cracks,missing lockrings, bent or brokenstuds, missing clamps or lugnuts.

• Check condition of tire: properlyinflated, no serious cuts, bulges,tread wear or any signs ofmisalignment; valve stem nottouching wheel, rim or brakedrum; valve cap in place.

• Check wheel bearing and hub:no obvious leaking on outside orinside wheel. Verify correct oillevel in hub.

Right Front Suspension

• Check condition of spring, springhangers, shackles, u-bolts: nocracks, breaks or shifting.

• Shock absorber condition.

Right Front Brake

• Condition of brake drum. Withbrakes released, look for anoticeable gap between liningand drum. This check cannot bemade if dust covers are in place.

• Condition of brake air hose:check for any chafing.

• Check slack adjuster andchamber pushrod travel. Withbrakes applied or released, lookfor conspicuously differentpositions of the slack adjustersfor proper brake adjustment.

• Check brake chamber mountingbolts and bracket.

Condition of Front Axle and SteeringSystem, Right Side

• No loose, worn, bent, damagedor missing parts.

Engine Compartmenr, RightSide• Check condition coolant and

heater hoses.

• Check condition of fan drivebelts.

• Check engine and surroundingareas for coolant, oil and fuelleaks.

• Check fuel seperator sight glassand drain if necessary. Check forleaks.

• Check wiring harness for sign ofdamage.

• Check air filter with brackets andhoses for loose connections ordamage. Check filter guage, ifmounted on the filter.

NOTEexample note

5 Right Saddle Tank AreaRight Fuel Tank(s)

• Securely mounted Diesel andDiesel Exhaust Fluid are notdamaged or leaking.

• Fuel lines secure and not leaking.Check that shut-off valves areopen.

• Tank(s) full of fuel. Cap on andsecure.

Condition of Visible Components

• Rear of engine: not leaking.

• Transmission: not leaking. Ifequipped with oil cooler, check




cooler, hoses and fittings forleaks.

• Check drive shaft.

• Exhaust system: secure, notleaking, not touching wires, fuelor air tubing.

• Frame and cross members: nobends, cracks or breaks.DPF/SCR check hoses andfittings for leaks.

• Air tubing and electrical wiring:secured against snagging andchafing.

6 Right Rear Vehicle AreaDual Wheels, One or Two Axles

• Check condition of wheels andrims. Especially look for cracks,missing lockrings, bent or brokenspacers, studs, missing clampsor lug nuts.

• Check condition of tires: properlyinflated, no serious cuts, bulges,tread wear or any signs ofmisalignment; valve stems nottouching wheels, rims or brakedrums; valve caps in place andno objects stuck between thewheels.

• Check that both tires are of sametype, for example, not mixed

radial and bias type and that theircircumferences are matched.

• Check wheel bearing and hub:no obvious leaking on outside orinside wheel.

Suspension

• Check condition of springs (leaf),spring hangers, shackles and u-bolts.

• Axle alignment.

Brakes

• Condition of brake drums. Withbrakes released, look for anoticeable gap between liningand drum. This check cannot bemade if dust covers are in place.

• Condition of brake hoses: checkfor any chafing.

• Check brake chamber mountingbolts and brackets.

• Check slack adjusters andchamber push rod travel. Withbrakes applied or released, lookfor conspicuously differentpositions of the slack adjustersfor proper adjustment.

• Check spring brakes.

7 Rear of Vehicle Area• Frame or cross members not

bent, cracked or otherwisedamaged or missing.

• Check that air tubing andelectrical lines are properlysecured to the frame with nodamage or chafing.

Lights and Reflectors

• Tail lights, brake lights and turnsignal lights: operating, clean andproper color.

8 Left Saddle Tank and LeftRear Vehicle Wheels AreaDual Wheels, One or Two Axles

• Check condition of wheels andrims. Especially look for cracks,missing lockrings, bent or brokenspacers, studs, missing clampsor lug nuts.

• Check condition of tires: properlyinflated, no serious cuts, bulges,tread wear or any signs ofmisalignment; valve stems nottouching wheels, rims or brakedrums; valve caps in place andno objects stuck between thewheels.

• Check that both tires are of sametype, for example, not mixed




radial and bias type and that theircircumferences are matched.

• Check wheel bearing and hub:no obvious leaking on outside orinside wheel.

Suspension

• Check condition of springs (leafor air), spring hangers, shacklesand u-bolts, no cracks, breaks orshifting.

Brakes

• Condition of brake drums. Withbrakes released, look for anoticeable gap between liningand drum. This check cannot bemade if dust covers are in place.

• Condition of brake hoses: checkfor any chafing.

• Check brake chamber mountingbolts and brackets.

• Check slack adjusters andchamber push rod travel. Withbrakes applied or released, lookfor conspicuously differentpositions of the slack adjustersfor proper brake adjustment.

• Check spring brakes.

Condition of Visible Components

• Transmission: not leaking.

• Driveshaft: looks OK.

• Exhaust system: secure, notleaking, not touching wires, fuelor air tubing.

• Frame and cross members: nobends, cracks or breaks.

• Air tubing and electrical wiring:secured against snagging andchafing.

Left Fuel Tank(s)

• Securely mounted and notdamaged or leaking.

• Fuel lines secure and not leaking.Check that shut-off valves areopen.

• Tank(s) full of fuel. Cap on andsecure.

Battery Area

• Open the battery box. Batterybox securely mounted to vehicle.

• Batteries secured againstmovement.

• Battery cases not broken orleaking. Battery cables free fromdamage.

• Tops of batteries and terminalsclean and free from foreignmaterial.

• If equipped, replace battery lidand make sure it is securelyfastened.

In the Cab

Check steps and grab handles forlooseness or breakage. Also, cleanthem if there is any substance thatmakes them slippery, which makescab entry/exit hazardous.

• Start the engine. If equipped,check that exhaust rain capopens when accelerating engine.

• Check gauges and tell-tale lightfunction. See the Instrumentsand Controls section.

• Check function of low airwarning.

• Check clutch function. Ifequipped, check for clutch brakefunction.

• Check windshield wipers andwashers and horns, includingback-up alarm, if equipped.

• Clean inside windshield, doorwindows and instruments. Cleanmirrors.

• Check temperature control anddefroster. If equipped, checkmirror heater.




• Check condition of warningtriangles, fire extinguisher andflares.

• Adjust the seat. Check mirroradjustment.

• Check safety belts for functionand damage.

• Apply service brakes. After initialdrop, pressure should holdsteady, or increase slightly, withengine at idle.

• Check steering wheel forexcessive free play.

• Check for loose items in the cab.Secure them if necessary.



SERVICE CHARTS

Service ChartsThe vehicle had a pre-deliveryinspection before being delivered to you,the customer. Regular maintenanceinspections should be continued. Themaintenance program and lubricationintervals that are listed in this manualmay not suit your operation. Contactyour nearest authorized dealer, who canhelp with designing a maintenanceprogram that works in your application.

• For regular service or maintenance,call the dealer in advance and arrangefor a service appointment. This gives thedealer time to schedule the correctequipment and provide a trainedtechnician to service the vehicle.• Setting an appointment can decreasevehicle downtime.• When in for service at an authorizeddealer, ask for outstanding safety relatedrecalls that relate to the vehicle. Thisservice is available only at an authorizeddealership.

NOTEIt is strongly recommended that you donot attempt to service, repair or maintainthe vehicle yourself unless you are fullytrained and have the proper tools,equipment and parts. Some proceduresare better performed by an authorizeddealer who has the proper equipment andtrained technicians.



SERVICE CHARTS

Scheduled Service DateScheduled Service Data

Scheduled Service Date Preventive Maintenance Work Completed

Date Mileage



SERVICE CHARTS

Noise Control LogNoise Control Log

Noise Control System Maintenance Log

Date Mileage Maintenance Performed Maintenance Facility



SERVICE CHARTS

Repair RecordRepair Record

Repair Record

Date Mileage Work Orderor InvoiceNo.

Dealer Notes



SERVICE CHARTS

Tire RecordTire Record

Date Type Front Type Rear Notes (Tire Pressure, Tread Depth)



SERVICE CHARTS

Fuel and Oil RecordFuel and Oil Record

Date Accumulated Oil Qty SAE No. Notes

Mileage Fuel Qty (Gallon)



SERVICE CHARTS

Engine DataEngine Data

Vehicle Identification Number (VIN)

Engine Model

Engine Serial Number

Primary Fuel Filter Part Number

Secondary Fuel Filter Part Number

Oil Filter Part Number, Full Flow

Oil Filter Part Number, By-pass

Air Cleaner Element Part Number

Coolant Filter Part Number

Fan Drive Belt Part Number

Accessory Drive Belt Part Number

Diesel Particulater Filter Part Number (IfEquipped)Diesel Oxication Catalyst Part Number (IfEquipped)



ENGINE

Precautions and Warnings

WARNINGMisuse or modification of a turbochargercan result in serious injury and propertydamage. In addition, extreme care mustbe taken to avoid foreign materialinduction, excessive exhausttemperatures and lack of lubrication.

CAUTIONThe maximum allowable engine speed islisted on the warning label on the sunvisor. DO NOT exceed 2,300 rpm.

CAUTIONIf a winterfront is needed, use only awinterfront that was designed for thisspecific chassis. Winterfronts are notrecommended, but can be used duringcold weather with sustained temperaturesbelow -25°C (-13°F).

CAUTIONBe sure to avoid high intake/exhausttemperatures when using winterfrontsunder normal operating conditions (abovefreezing). The restriction of airflow cancause higher exhaust temperatures,power loss, excessive fan usage andreduced fuel economy.

CAUTIONIf a winterfront is used, a Mack-approvedexhaust pyrometer must be installed andclosely monitored while the engine is inoperation. Do NOT exceed the maximumtemperature indicated by the red line onthe gauge. To reduce exhausttemperature, downshift or reduce enginepower and open the winterfront.

CAUTIONDo not permit a heavy load to drive theengine above the governed speed.

CAUTIONOperate in a gear low enough to allow theengine to accelerate to (or maintain)governed speed when applying thethrottle.

DANGERBefore working on or inspecting a vehicle,set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result inunexpected vehicle movement and cancause serious personal injury or death.

DANGERDO NOT attempt to repair or service thisvehicle without having sufficient training,correct service literature and the propertools. Failure to follow this could lead topersonal injury or death, or making yourvehicle unsafe.

NOTERead all safety information before workingon the vehicle.

NOTEDo NOT use extended-life coolant inengines equipped with a coolantconditioner filter. A coolant filter thatcontains no supplemental coolantadditives (SCA) is available for use whenextended-life coolant is used.



ENGINE

Service Planning and SchedulesPreventive maintenance is vital to the lifeof your new vehicle. This section of theOperator Handbook covers items ofimportance concerning the proper careof your vehicle. A well-run maintenanceand lubrication program is the best way

to ensure a long life of productiveoperation.

By performing daily checks andobserving the equipment while inoperation, minor defects can be

corrected before putting the equipmentinto operation.

If you have any questions concerningthe proper care, maintenance andlubrication of your vehicle, contact yourlocal dealer.

Engine Service, MackComponent Operation Km (Miles) / Maximum Months/HoursFuel Filter Change Each oil change*

Water Separator (Engine Mount) FilterChange

Each oil change*

Fuel / Water Separator (Chassis Mount) Change Each oil change*

Fuel Tank Ventilation Filter Change Every 12 Months

Fuel Tank Ventilation Filter (Stanchion Mount) Change Every 12 Months

Air Filter (Engine) Change At maximum restrictions as indicated on gauge, or 12months

Coolant (Normal or Heavy Duty ) Change 500 000 km (300,000 mi) or 24 months whichever comesfirst

Coolant (Severe Duty) Change 240 000 km (150,000 mi) or 12 months whichever comesfirst

Coolant, Extended Life (ELC) Change 1 609 344 km (1,000,000 mi) or 96 months, whichevercomes first

Coolant Filter Change At every engine oil change.

Coolant Filter Extended Life (ELC) Change 240 000 km (150,000 mi) or 12 months, whichever comesfirst

Coolant Conditioner Change Traditional coolants requiring Supplemental CoolantAdditive (SCA)80 000 km (50,000 mi) or 6 months

Valves/Injectors *** InitialAdjust

240 000 km (150,000 mi) or 12 months, whichever comesfirst



ENGINE

Component Operation Km (Miles) / Maximum Months/HoursValves/Injectors *** Adjust 500 000 km (300,000 mi) or 24 months, whichever comes

firstDrive Belts (Normal or Heavy Duty) Change 500 000 km (300,000 mi) or 36 months, whichever comes

firstDrive Belts (Severe Duty) Change 240 000 km (150,000 mi) or 12 months, whichever comes

firstAccessory Drive Belt (Normal or Heavy Duty) Change 500 000 km (300,000 mi) or 36 months, whichever comes

firstAccessory Drive Belt (Severe Duty) Change 240 000 km (150,000 mi) or 12 months, whichever comes

firstAftertreatment Diesel Exhaust Fluid (DEF) Tank Flushing and FillerNeck Filter

Clean 240 000 km (150,000 mi) or 4,500 hours, whichever comesfirst

Aftertreatment Diesel Exhaust Fluid (DEF) Pump Filter** Change 240 000 km (150,000 mi) or 4,500 hours, whichever comesfirst

Aftertreatment Diesel Particulate Filter (DPF) (Normal or Heavy Duty) Clean 650 000 km (400,000 mi) or 10,000 hours, whichevercomes first

Aftertreatment Diesel Particulate Filter (DPF) (Severe Duty ) Clean 400 000 km (250,000 mi) or 4,500 hours, whichever comesfirst

Aftertreatment Hydrocarbon Doser (If equipped) Clean 240 000 km (150,000 mi) or 4,500 hours, whichever comesfirst

*Under certain conditions (for example, irregular fuel quality), the fuel/water separator filters may require more frequent replacement.

**Under certain conditions (for example, dirt and dust) filters may require more frequent replacement.

***Valves must be adjusted whenever the rocker shaft has been removed and reinstalled for any reason.



ENGINE

Engine Overview, MP7™ LeftSide View

1 Breather Tube

2 Intake Manifold

3 Air Compressor

4 Power Steering Pump

5 Fuel Pump

6 Engine Control Module (ECM)

7 Fuel Filter

8 Fuel/Water Separator

9 Fuel Filter

10 Hand-Priming Pump

11 Crankcase Ventilator

12 Alternator

13 Alternator/AC Compressor Belt

14 AC Compressor

15 Fan/Coolant Pump Belt

16 Intake Throttle Valve

17 EGR Mixing Chamber



ENGINE

Engine Overview, MP7™Right Side View

18 Exhaust Manifold

19 Thermostat

20 Belt Tensioner

21 Coolant Pump

22 Coolant Filter

23 Oil Pan

24 Oil Filters

25 EGR Cooler

26 Turbocharger

27 Starter Motor

28 EGR Valve

29 Valve Cover



ENGINE OIL

GeneralKeep the engine oil at the proper leveland change it at the recommendedintervals. Always replace the oil filters atthe same time as when the oil ischanged.

Oil QualityEngine oils that meet or exceed thestandards given by American PetroleumInstitute (API) for the oil classificationsare listed in this manual. Only oilslicensed to carry the API symbol shouldbe used. Lubricants meeting APIstandards have provided maximumengine life when used together with therecommended oil and oil filter changeintervals.

EO-O Premium Plus (or VDS-4) dieselengine oil is mandatory for use in allcurrent emission compliant engines.Chassis equipped with a DieselParticulate Filter (DPF) require the use ofUltra Low Sulfur Diesel (ULSD) fuel. EO-O Premium Plus oils exceed the APIservice category CJ-4.

CAUTIONDO NOT add extra oil additives. Additivessuch as break-in oils, top oils, graphitizersand friction-reducing liquids are notnecessary and can harm the engine.

Oil Change IntervalsThe length of time an engine canoperate before an oil change dependson the quality of oil used, the type of fuelused, fuel consumption, engine oilconsumption, vehicle application, levelof dust in the air and fuel consumption.The change intervals given in thismanual are maximum intervals. If thevehicle is operating in heavy-duty, dustyor off-road conditions more frequent oilchanges should be scheduled.

For additional information about oilchange intervals and approved oils,contact a certified dealer.

NOTEOil filters should always be changed whenchanging oil.

Oil FiltersThere are three filters on the engine, oneof which is a bypass filter. This shouldbe changed at the same time as the full-flow filter(s).

CAUTIONOil filters are designed to provide theproper level of filtration and protection forthe engines. Filters that do not meet thesame stringent requirements may voidengine warranty.

1 Spin-Off Oil Filters

Synthetic LubricationSynthetic oils are offered by some oilsuppliers as an alternative to thetraditional, petroleum based oils forengines. These oils may be used inMack engines, provided they meet thequality levels specified on the previouspages.

The use of synthetic oils does not permitthe extension of the recommended oilchange intervals. It is the contaminationrate, i.e., soot, and the depletion ofadditives, rather than base oil qualitythat determines the useful engine oil lifeand therefore the oil change intervals.

Oil ViscosityThe viscosity grade defines thethickness of the oil. The oil must be thinenough at low temperatures for easycold starts and thick enough to protect



ENGINE OIL

at high temperatures. An oil is not fullydefined until both the oil quality (seeprevious pages) and the viscosity gradeare specified.

Choose the viscosity grade for thetypical ambient temperature for theapplication.Multigrade oils have a broadrange that suit operation in changingtemperature. The standard engine oilweight is 10W/30.

The engine viscosities shown in theviscosity/temperature table isrecommended.

Oil Additives

CAUTIONExtra oil additives must never be added toany engine oil used. Additives such asbreak-in oils, top oils, graphitizers, andfriction reducing liquids are not necessaryand may even harm the engine.

Using oils to the quality standardsrecommended in this manual makes theuse of extra oil additives unnecessary,as these oils already contain a balancedtreatment of additives.

Oil ConsumptionOnce the engine is stopped, check theoil level daily. If the engine has just beenstopped and it is warm, waitapproximately five minutes to allow theoil to drain back to the oil pan beforechecking. Add oil as necessary.

NOTEDO NOT overfill engine with oil.

All diesel engines are designed toconsume some oil, so it is normal to addoil periodically. An engine used in heavy-duty operation will consume more oilthan one in normal operation.

Oil Change

WARNINGA hot engine or engine oil can bedangerous. Serious burns can result fromcontact with a hot engine or oil. Takeprecautions when draining the oil. Weargloves or let the engine cool down beforedraining.

WARNINGWhen draining the oil, use the proper toolsand keep away as far as possible. Raisethe elbow so the forearm is parallel to theground to prevent oil running down thearm, causing burns.



ENGINE OIL

CAUTIONAlways dispose of all lubricants (motor oil,coolant, gear box oils, etc.) and filtersaccording to Federal and local regulations.Used oil disposed of in nature orwaterways contaminates our drinkingwater and kills wildlife.

CAUTIONProlonged contact with used engine oilmay be harmful. Use rubber gloves whenhandling used oil. Wash skin thoroughly ifit comes in contact with used oil.

It is important to drain as much oil aspossible. Try to change oil immediatelyafter driving, when the oil is warm.Always replace the oil filters whenchanging oil.

Oil Filters Change

WARNINGHot oil can cause severe burns. DO NOTallow hot oil to contact the skin. Whenchanging oil, wear protective gloves.

CAUTIONMack-branded oil filters are designed toprovide the proper level of filtration andprotection for Mack engines. Filters thatdo not meet the same stringentrequirements may cause unsatisfactoryresults.

1 Coat the filter gasket with oil.

2 Install the filter and turn it by handuntil the gasket makes contact withthe sealing surface.

3 Manually turn the filter an additional3/4 to one full turn.

Checking Oil Level

NOTEDO NOT let the oil level fall below themarking on the dipstick. DO NOT overfillso the level is above the upper marking onthe dipstick. This could lead to excessiveoil temperature and/or poor crankcasebreather performance.

Ensure that the vehicle is parked on levelground before checking the oil level.Wait five minutes after shutting off theengine, then proceed with checking oil.

1 Oil Dipstick



ENGINE OIL AND FILTER INTERVALS

Powertrain Operating Conditions (POC)Transport cycle Long distance driving Distribution Construction sites 1

Regional City

CMT ≤ 44 45 - 70 71-80 > 80 ≤ 32 33–44 45–70 ≤ 32 ≤ 32 33–44 45–80 >80

Topography PF H PF H PF H PF/H H H H VH

POC L2 M3 H3 S3 S3 VS VS M H S S H S VS VS+

Maximum permitted fuel consumptionPOC L M H S VS VS+

l/100 km (quarts/miles) ≤ 33 (35) ≤ 39 (41) ≤ 50 (53) ≤ 64 (68) > 64 (68) -

km/liters (miles/quarts) ≥ 3.0 (1.8) ≥ 2.5 (1.5) ≥ 2.0 (1.2) ≥ 1.5 (0.9) ≥ 0.8 (0.5) -

Note: In some regions, B-double or B-train applications with GCW > 55 ton shall be classified as POC S.Note: The POC determined for a particular application shall be used for all components to which POC is applied. If there is a conflict with thefuel consumption interval for the determined POC and the actual fuel consumption (if known), then the actual fuel consumption shall decidethe POC for the vehicle.1 Typical vehicle configurations normally involved in Construction applications are sugar cane, tipper, dumper, swap carrier, concrete mixer orrefuse bodies.2 If vehicle speed frequently exceeds 90 km/h (56 mph), move to the next higher POC classification.3 If the combined PTO (at zero vehicle speed) and idle time exceeds 25% of total operating time, move to the next higher POC classification.

MP7™ EnginesEngine Operating Condition Severe Duty Heavy Duty Normal DutyTotal Fuel Consumption (L/100 km) >50 <50 <39

Total Fuel Consumption (mpg) <4.7 >4.7 >6.0

Engine Oil and Filter Change Interval - 42 L (44quarts) oil capacity

45 000 km (25,000 mi) 625hours

60 000 km (35,000 mi) 1,000hours

75 000 km (45,000 mi)1,300 hours

NOTEUsing oils that meet EO-O Premium Plusquality standards at all times, isrecommended.

NOTEIf idle time is greater than 30%, use thenext lower change interval.



OIL CAPACITY TABLE AND VISCOSITY CHARTS

NOTEUse the information in the table below todetermine the operating condition andusage applicable to your vehicle.

Oil Fill CapacityFilterVolume

PanVolume

Oil ChangeFill

11LSteel

6 liters (6quarts)

30 liters (32quarts)

36 liters (38quarts)

NOTECheck the dipstick and top-off as needed.

Oil ViscosityThe viscosity grade defines thethickness of the oil. The oil must be thinenough at low temperatures for easycold starts and thick enough to protectat high temperatures. An oil is not fullydefined until both the API qualityclassification and the viscosity grade arespecified.

Choose the viscosity grade for thetypical ambient temperature for theapplication. Multigrade oils have a broadrange that suit operation in changingtemperature. The standard oil weight forMack® engines is 10W/30.

Mack® recommends the viscositiesshown in the viscosity/temperature tablefor Mack® engines.



ENGINE STORAGE

If the vehicle must be parked for aperiod (more than 30 days), protect it asfollows:

1 Drain the engine oil.

2 Fill up to the proper level with oil ofthe recommended quality andviscosity.

3 Fill up the fuel tanks with therecommended grade of fuel.

4 Run the engine for two minutesaround 1000 rpm. Shut the enginedown. DO NOT drain the oil after thisrun.

5 Check the coolant for proper levelsof antifreeze and inhibitor protection.Service as necessary.

6 Seal all engine openings usingprotective covers.

To return to service an engine preservedin this manner, remove previouslyinstalled protective covers. Check allfluid levels and if necessary replaceengine oil contaminated bycondensation.



ELECTRICAL SYSTEM

Batteries

WARNINGBattery posts, terminals and relatedaccessories contain lead and leadcompounds, chemicals known to theState of California to cause cancer andreproductive harm. Wash hands afterhandling.

WARNINGAlways wear eye protection when workingaround batteries to prevent the risk ofinjury due to contact with sulfuric acid oran explosion.

CAUTIONWhen using a pressure washer to cleanthe vehicle, do not direct the spray atelectrical components in the enginecompartment such as the alternator,starter and compressors. Water sprayfrom pressure washers can damageelectrical components.

A maintenance-free battery does notrequire the addition of water for itsnormal expected life. Typical featuresinclude heavy-duty construction andwrought lead-calcium grid to resistvibration, shock, overcharge, heat andthermal runaway. Nevertheless, these

batteries are vulnerable to the ravages ofcold weather operation if totally ignored.

Battery RatingBe sure that the batteries used in thisparticular vehicle are rated for thespecified Cold Cranking Amperes(CCAs) necessary to ensure reliable coldweather starts. This is important, sinceeven well-maintained batteries chilled to– 18 °C (0 °F) may temporarily becapable of providing only 40% of theirrated capacity at 27 °C (80 °F).

Keep the terminals clean to preventformation of power-robbing corrosion. Inwinter, to avoid freezing the electrolyte,the battery must be fully charged. A fullydischarged battery will freeze solid at –5 °C (23 °F) and possibly sustainpermanent damage.

Before the onset of cold weather, besure to protect this vital component bymonitoring its condition as well as

inspecting the charging and startingsystems.

Battery WarmerA battery warmer can be added to raisethe temperature of the battery core andfacilitate quick starting in cold weather.

Battery ConditionThe first procedure when testing abattery is to check for external damagesuch as a cracked case, loose orcorroded terminals, or signs ofexcessive gassing or overcharging.

A battery must be fully charged before aload test is performed. Test the batterywith a hydrometer to determine the levelof charge.

On maintenance-free batteries equippedwith a built-in hydrometer (eye), thebattery condition is interpreted asfollows:



ELECTRICAL SYSTEM

1 Green Dot visibleAny green appearance should beinterpreted as a green dot and meansthat the battery is at or above a 65%state of charge and is ready for use ortesting. This does not automaticallymean that the battery is in goodcondition.2 Green Dot not visible (Black Dot)This indicates that the battery is below a65% state of charge and must becharged before testing. A black dot doesnot mean that the battery isautomatically bad.3 Clear or Light YellowThis means that the electrolyte level isbelow the level of the built-inhydrometer, which may have beencaused by tipping of the battery, acracked case, or overcharging. Thisbattery should be replaced.

Electric and ElectronicSystems


Check regularly around the engine andengine compartment for loose or frayedwires. Have all loose or frayed electricalwires and cables repaired beforeoperating the vehicle.

Grounding PracticesProper grounding for vehicle and engineelectrical and electronic systems isnecessary for proper vehicle and engineperformance and reliability. Impropergrounding will result in uncontrolled andunreliable electrical paths.

Uncontrolled engine electrical circuitpaths can result in damage to mainbearings, crankshaft journals surfacesand aluminum components.Uncontrolled electrical circuit paths canalso cause electrical noise which maydegrade vehicle and radio performance.

Operating engines without the engine-to-frame ground strap installed cancause damage to the engine. To preventelectrical discharge damage, check to

make sure the engines electrical systemhas an engine-to-frame ground strap. Allground connections should be tight andfree of corrosion.

DANGERThe engine uses high voltage to theelectronic unit injectors. DO NOT come incontact with the unit injector terminalswhile the engine is running. An electricshock can cause an involuntary musclespasm and cause loss of balance and fallsleading to severe personal injury or death.

Electronic Engine ControlSystemTampering with the electronic systeminstallation can be dangerous and couldresult in personal injury or death and/orengine damage. It is very important totake the proper precautions with theelectrical and electronic system whencharging the batteries, jump-starting orperforming electric welding on thevehicle.

This vehicle is equipped with monitoringfeatures that may cause reduced poweror shutdown under certain conditions.Monitoring and idling features can onlybe programmed and/or changed withelectronic service tools and passwords.

Certain features, such as low oilpressure, high coolant temperature orlow coolant level could cause the engine



ELECTRICAL SYSTEM

power and/or vehicle speed to be limitedand the engine may also shut down.

DANGERFailure to take necessary action when theSTOP tell-tale is on can ultimately result inautomatic engine shutdown and loss ofpower steering assist. Vehicle crash canoccur, resulting in personal injury or death.

Wiring Harness / Cable andConnector ProtectionIf corrosion is seen at any external ring-type terminal connections, such asthose used at the starter, alternator,chassis and/or engine grounds, etc.Corrosion protectant must be applied tothe connection after disconnecting,cleaning and reconnecting the ringterminal. Additionally, corrosionprotectant should be applied to anyring-type terminal connector followingany type of service procedure whichinvolved disconnecting/reconnecting thering terminals (such as componentreplacement, troubleshooting, serviceand repair, etc.).

To help protect your vehicle's externalhigh amperage electrical cables andconnections from corrosion due to theeffects of newer salts (calcium chlorideand magnesium chloride) on the

roadways, use an approved corrosioninhibitor.

Coat all high amperage (positive andground) exposed electrical connectionsat a minimum of every 6 months or,whenever the connector has beendisassembled. The following listcontains the recommended connectionsthat should be liberally coated with thecorrosion inhibitor;

• Battery connections

• Battery main shut off switchconnections

• Maxi and/or Mega fuse connections

• All ground stud connections

• Electrical pass-thru connections

• All alternator connections

• All starter connections

• Intake preheater and preheater relayconnections

• Electrical power inverter connections

All connections should be cleaned andfree of previously applied inhibitors, oil,dirt, dust or other contaminants prior toapplication. Allow time for the product todry before use (drying time may varydepending temperature, humidity, etc.)

ChargingCharging should be conducted carefullyunder controlled conditions. Nevercharge a frozen battery. If a frozenbattery is suspected, thaw it in a warmarea for several hours before charging.

The following chart shows the normalcharging times necessary to reach a fullcharge at 26 °C (80 °F). In coldertemperatures, the necessary chargingtime may increase.



ELECTRICAL SYSTEM

Battery ChargingOpen Circuit Voltage Battery Specific Gravity* State of Charge Charging Time to Full Charge at 80°F**

at 60amps

at 50amps

at 40amps

at 30amps

at 20amps

at 10amps

12.6 1.265 100% Full Charge

12.4 1.225 75% 15 min 20 min 27 min 35 min 48 min 90 min




*Correct for temperature

**If colder, it will take longer



ELECTRICAL SYSTEM

Completely Discharged BatteriesExtremely cold or completely dischargedbatteries may not initially show a chargesince the electrolyte is nearly pure waterand, therefore, a poor conductor. As theacid level in the electrolyte increasesduring charging, the charging current willalso increase. Use the followingprocedure when charging a completelydischarged battery:

1 Measure the voltage at the batteryterminals. If it is below 10 volts,current will be very low and may notshow up on many battery chargerammeters.

2 Set the charger on the high setting.

3 Some chargers have a polarityprotection feature which preventsaccidental reversal of the chargerleads. A completely dischargedbattery will not have enough voltageto override this feature, making itappear that the battery will notaccept a charge. Check the chargermanufacturer's instructions on howto bypass this feature.

4 Once the battery starts to accept acharge, the charging rate will risevery rapidly. Carefully monitor theammeter to prevent too-high acharging rate.

5 Proceed to charge battery at one-tenth of its rated capacity for one-half hour. Example: For battery ratedat 64 (amps-hour), charge at 6.4 ampsetting.

NOTEBatteries with very low voltage (below11.6 volts) or those that do not initiallyaccept a charge are not necessarilydefective. Batteries that have beendischarged for long periods of time maybe heavily sulfated or hydrated (containinglead shorts that cause the battery to self-discharge). To accept a charge, batterieswith either of these conditions may requirea longer charging time or a very high initialcharge.

Use the following chart to determine thetime required for the battery to beginaccepting a measurable charge. (If thebattery has not started to accept acharge after the specified time, it shouldbe replaced.)

Charger Voltage Hours16.0 or more Up to 4

14.0 to 15.9 Up to 8

13.9 or less Up to 16

Load TestA battery must be fully charged beforeperforming a load test. To load-test abattery follow the manufacturer's writteninstructions.

Lighting

WARNINGUsing incorrect bulbs or lamps may resultin failures that could lead to a fire or avehicle accident caused by improperlighting.

Check all lights on the vehicle daily forproper function. Replace burned outinserts and bulbs. Replace any brokenor cracked side or rear reflectors.Headlights should be checked for aim atleast once per year.



ELECTRICAL SYSTEM

Precautions When InstallingElectrical EquipmentConnecting electrically powered orelectrically controlled equipment to avehicle may cause interference withother vehicle electrical or electronicequipment (such as ABS systems,Rollover Stability Systems, etc.). Theamount of interference depends uponthe operating frequency of any newsignals and the degree to whichtransient signals are coupled to thevehicle system.

NOTEWhenever new electrical equipment isinstalled, it is the obligation of the installerto ensure that the new equipment doesnot interfere with the proper operation ofall other electrical systems on the vehicle.

If new electrical equipment is installed, avehicle checkout procedure should beperformed.

1 Perform the checkout procedureunder the following conditions:

• Engine running

• Brake system air pressure inoperating range

• Vehicle stationary

• Brake pedal fully depressed

2 Operate the new equipment under allstarting, running and shutdownconditions.

3 Listen for signs of air exhaustingfrom the ABS modulator valves(which is an indication of aninterference condition).

4 Correct all interference conditionsbefore operating the vehicle.

NOTEThe center pin of the standard seven-pintrailer electrical connector has beenstandardized as the dedicated connectionfor uninterrupted power for trailer ABS.This pin is always powered when thetractor ignition is turned on.

DANGERSome trailers manufactured prior to thetrailer ABS regulations may use the centerpin to power certain trailer auxiliaryequipment. The possibility exists that thisauxiliary equipment may be unexpectedlyactivated by the truck or tractor electricalsystem, resulting in personal injury ordamage to equipment. Caution must beused when connecting the trailer electricalconnector to ensure that power to thecenter pin will not unintentionally activateany trailer auxiliary equipment.



TURBOCHARGER / CHARGE AIR COOLER

DANGERIf oil leaks internally from the turbochargerto the engine intake, the oil acts as a fuel.Watch for excessive exhaust smoke. DONOT operate engine until problem iscorrected. There is no way to regulate theengine speed if it runs on oil and it mayover speed. Loss of control of vehicle maylead to an accident causing severepersonal injury or death.

WARNINGDO NOT remove, attach, or tightenturbocharger air intake ducting while theengine is operating, or operate the enginewhile the ducting is removed. Workingaround the turbocharger with the ductingremoved may cause severe personalinjury.

Visually inspect turbo mountings, intakeand exhaust ducting and connectionsfor leaks on a daily basis. Check oil inletand outlet for leaks or signs ofrestrictions to oil flow. Check for unusualnoise or vibration. If any faults aredetected, do not operate the engine untilthe cause is determined and repaired.

Charge Air Cooler and RadiatorPackage Cleaning

WARNINGAlways wear eye protection when cleaningradiator, charge-air cooler and condenser.Failure to follow this recommendation mayresult in eye injury.


Periodically inspect the front of theradiator/charge-air-cooler package. Overtime, there may be a build-up of dirt,mud, insects, etc., between the radiatorand charge air cooler.

Over time the reduced air flow reducesthe heat transfer from the componentsto the air. This increases the load on thefan and air conditioning compressor andcan result in engine overheating andother performance related problems,such as high fuel consumption. Inspectfor build-up and contact your authorizeddealer, if necessary.

The simplest method to clean thepackage is to use air pressure or a water

stream. This should be done from theback of the core. Air pressure should notexceed 30 psi (200 kPa) for radiator andcharge air cooler cores. The use of a fincomb is also a good tool to loosen bugsand dirt from the fins. If dirt cannot becleaned off with this procedure, consultyour dealer.

Inspect the charge air cooler for cracksat every inspection. DO NOT operate thevehicle with a damaged or brokencharge air cooler. To do so would voidthe warranty and the engine will notmeet emission regulation requirements.



DRIVE BELT REPLACEMENT INTERVALS

Check pulleys for debris, clean asneeded.

Rib CrackingAn in-service poly V-belt will go throughseveral phases of cracking during its life.After an extended time in service, minorrib cracks may appear, usually one ortwo cracks per inch. This cracking isnormal.

Belt With Minor Cracking

Belts should not be replaced unless theribs exhibit severe multiple cracking asshown below. Multiple cracking will leadto rib chunking.

Belt With Multiple Cracking

Belt With Severe Cracking

Rib Sidewall GlazingWhen the belt ribs appear to have ashiny surface that is hard and brittle, it isusually an indication of belt slippage.This is attributed to inadequate tensionand/or extreme temperature. Both theseconditions will lead to severe crackingand belt failure, often with little advancewarning. If this occurs, locate the causeand correct before installing a new belt.

Belt WearAccelerated wear on any part of the belt(fabric backing, tensile cord or rib

rubber) is a concern and should beinvestigated for cause, and correctedbefore installing a new belt.

Possible Causes of AcceleratedBelt Wear• Drive belt performance will beadversely affected when misalignmentexceeds 1/16 inch for every 12 inches ofbelt span.• Belt length must be correct.• Environmental conditions,temperature, exposure to engine fluids,etc.• Abrasive materials, small stones, metalshavings, etc.

Foreign ObjectsAny object protruding in the path of thebelt drive and contacting the belt willcause damage and eventual failure.Locate the object before installing a newbelt.

Noise, Vibration and Harshness(NVH)Poly V-belt drive systems were designedto prevent Noise, Vibration andHarshness (NVH) problems. Fieldproblems, however, which may berelated to NVH causes occasionallyoccur.



DRIVE BELT REPLACEMENT INTERVALS

Possible Causes of (NVH)Insufficient belt tension may create ahigh-pitched howl (squeal) or raspingsound during engine acceleration ordeceleration.

Misalignment may cause a chirpingnoise, especially at, or near, idle speed.Rigid bracketing of accessories is amust for reasonably vibration-free beltspans. Some span vibration is to beexpected during the range of enginespeed and accessory loading.

WARNINGFailure to follow recommended applicationinformation and recommendedprocedures for installation, caremaintenance and storage of belts mayresult in failure to perform properly andmay result in damage to property andserious bodily injury. Make sure the beltselected for any application isrecommended for that service.



DRIVE BELT ROUTING

Drive Belt InstallationTo install a poly V-belt, swing theautomatic tensioner to the full sprungposition (fully toward the install stop),then place the belt over the pulleys.Slowly return the automatic tensionerback to its original position. Do not allowthe tensioner to snap against the stops.Before installing the new belt, ensurethat the pulley grooves are clean andfree of debris.

Drive Belt RoutingCertain model chassis equipped withMP7™ engines utilize a 10-rib belt on 12-rib pulleys. When replacing the belt, thebelt must be installed against the rearface of the pulley (edge of pulley closestto the engine).

1 Install 10-rib belt against rear edge of 12-ribpulley.

Accessory Drive Belt RoutingAccessory drive belt and main beltrouting with and without air conditioning.This diagram is located in a clear areaon the outside of the left frame betweenthe radiator and center line of the frontaxle.

1 Crankshaft Pulley

2 Automatic Tensioner

3 Idler Pulley

4 Coolant Pump

5 Main Drive Belt

6 Fan Drive

7 Idler Pulley (when applicable)

8 Accessory Drive Belt

9 Automatic Tensioner

10 Alternator

11 Air Conditioner Compressor (if equipped)

Automatic Belt TensionerThe automatic belt tensioner is designedto maintain proper belt tensionthroughout the life of the tensioner. Thebelt tensioner cannot be adjusted orrepaired. At each D inspection interval oronce per year, whichever occurs first,check the following:• With the belt on the drive, check thefollowing:Check to see if the tensioner is restingagainst the install stop or the free-armstop. If the tensioner is resting againsteither stop, the tensioner must bereplaced.

1 Install Stop

2 Free Arm Stop

On main drive belt tensioners, checkbelt tracking. If the belt is tracking all theway to one side of the tensioner pulley(either the front- or back-side), replacethe tensioner. Belt tracking can bedetermined by looking at the witness



DRIVE BELT ROUTING

mark (the shiny area on the pulley wherethe belt rides). The witness mark shouldbe approximately the same width of thebelt.

1 Acceptable (Witness Mark ApproximatelySame Width as Belt)

2 Not Acceptable (Witness Mark Tracking OffEdge of Pulley)

Remove the belt by using a 1/2 inchbreaker bar to pull the tensioner back tothe install stop. Slowly return thetensioner to the free-arm stop.

With the belt removed, use the breakerbar to slowly pull the tensioner from thefree-arm stop to the install stop and thenslowly releasing it back to the free-armstop. Any excessive roughness orhesitancy noticed while performing thischeck indicates that the tensioner mustbe replaced.

Check for metal-to-metal contact asfollows:

Check for contact between the arm andthe spring case. Replace if metal-to-metal contact is seen.

1 Free-Arm Stop Position

2 Contact between Arm and Spring CaseCheck.

Check for metal-to-metal contactbetween the arm and the end cap.Replace if contact is seen.

1 Contact between Arm and End Cap Check



COOLING SYSTEM

DANGERCoolant is toxic; risk of poisoning. DONOT drink coolant. Use proper handprotection when handling. Keep coolantout of reach of children and animals.Failure to follow these precautions cancause serious illness or death.

WARNINGDO NOT raise the engine hood if you seeor hear steam or coolant escaping fromthe engine compartment. Wait until steamor coolant cannot be seen or heard beforeraising the hood.DO NOT remove the coolant fill cap if thecoolant in the surge tank is boiling. Also,DO NOT remove the cap while the engineand radiator are still hot. Scalding fluidand steam may be blown out underpressure if the cap is taken off too soonand can cause personal injury.

WARNINGCoolant may be combustible. Coolantleaked or spilled onto hot surfaces orelectrical components can cause a fire.Clean up coolant spills immediately.

CAUTIONMack Trucks does not recommend usingplain water in the cooling system. Wateralone is corrosive at engine operatingtemperatures and does not provideadequate boiling protection. The enginemay develop corrosion and cavitationproblems in the engine and radiator, andthe boiling point of the coolant is loweredcompared to a proper antifreeze andwater mixture. Failure to follow MackTrucks cooling system care/maintenancerecommendations can render the warrantyinvalid.

The cooling system plays an importantrole in overall engine performance bykeeping the engine within the normaloperating temperature range; hotenough for efficient combustion, andcool enough to prevent engine damagecaused by overheating. Good preventivemaintenance practices, along withmonitoring cooling system performance,go a long way in preventing enginedamage that could result from coolingsystem problems. The maintenanceitems and tests outlined in this sectionshould be performed at the intervalsspecified to ensure optimumperformance from the cooling system.

Surge Tank Cap (CabOver)The surge tank cap on your vehicle islocated on the left-hand side of thechassis, mounted on a stanchion to the

rear of the cab. This surge tank utilizes astandard radiator pressure cap. Checkthe coolant level regularly, making surethe coolant is visible in the sight glasslocated on the side of the tank. Removethe radiator cap and inspect the gasketfor any defects that would affect sealing.Also, pressure-test the cap using asuitable cooling system and radiator captester.

Surge tank cap pressure specificationsare as follows:

• MP7™ Engines 16-lb. pressure cap

1 Tank Cap

WARNINGDO NOT remove the fill cap while thecooling system is hot. Allow the system tocool sufficiently before removing. Turn thefill cap slowly counterclockwise and waitfor the pressure in the system to dissipate.After the pressure has dissipated,completely remove the cap.



COOLING SYSTEM

The main purpose of coolant is totransport heat from the hot parts of theengine to the radiator and to protect thecooling system from corrosion.

In addition to this, the coolant must:

• Protect against pitting and cavitationerosion damage of the water pump andcylinder liners.

• Protect against freezing and boiling.

• Prevent formation of scale, sludgedeposits and clogging.

• Be harmless to polymer materials andseals in the cooling system.

• Maintain its liquid properties in coldclimates.

Many engine failures can be traced backto a problem in the cooling system. If thecoolant level is allowed to go below thebottom of the tank, there is the risk ofthe engine shutting down. See theoperators manual for more informationon the warning functions.

NOTEAlways dispose of coolant according toFederal and local regulations. Take allused coolant to a recycling or wastecollection center.

Coolant mixture consisting of anantifreeze solution in water should be

used year-round to provide freeze andboil-over protection.

NOTEDO NOT use antifreeze formulated forautomobile gasoline engines. These havea very high silicate content that will clogthe radiator and leave unwanted depositsin the engine.

Coolant System Capacities

CAUTIONCapacities may vary due to hoses andsize of radiator, as well as accessorycooling equipment. After running theengine until normal operating temperatureis reached, check the coolant level andadd coolant as needed.

Use the chart shown in conjunction withthe Ethylene-Glycol and Propylene-Glycol Protection Charts in this sectionto determine the amount of antifreezeneeded to protect your vehicle.

Coolant Capacity MRU WithMP7™

ChassisModel

Engine Model CoolantCapacity in

Liters(Quarts)

MRU MP7™ Manualtransmission w/out

auxiliary coolingpackage

39 (41)

MP7™ Manualtransmission withauxiliary cooling

package

48 (51)

MP7™ Automatictransmission withauxiliary cooling

package

58 (61)

Use the following antifreeze protectioncharts to determine the percentage ofantifreeze needed to achieve specificprotection levels for various coolantsystems.

Ethylene-Glycol Protection ChartEthyleneGlycol

Ambient Air Temperature

40% -24ºC (-12ºF)

50% -37ºC (-34ºF)

60% -52ºC (-62ºF)



COOLING SYSTEM

Propylene-Glycol ProtectionChartPropylene-Glycol

Ambient Air Temperature

40% -21ºC (-6ºF)

50% -33°C (-27°F)

60% -49°C (-56°F)

A well functioning and maintainedcooling system is as important to theengine as performing regular oil changesor using good fuel. To get the best resultuse quality products and service thesystem at the correct intervals. Pleaseread this section carefully.

Keep the radiator (including charge aircooler) and the frontal area free frombugs, dirt, leaves, etc.

Check the coolant level in the tankregularly. Fill the tank as necessary withthe correct coolant.

Inspection of the whole cooling systemis important. Check for swollen ordeteriorated heater and radiator hoses,loose hose clamps and connections,and coolant leaks.

DANGERDO NOT work near the fan with the enginerunning. The engine fan can engage at anytime without warning. Anyone near the fanwhen it turns on could be seriouslyinjured. Before turning on the ignition, besure that no one is near the fan.

CAUTIONNever add coolant to a hot or overheatedengine. Engine damage can result. Allowthe engine to cool first.



COOLING SYSTEM

AdditivesAdditives help prevent rust, scale andmineral deposits from forming. Additivesalso protect metals from corrosion,prevent water pump and cylinder linercavitation and contain anti-foamingagents. Additives are depleted duringnormal engine operation and need to bereplaced. For non-extended life coolantmixture, this means the addition ofSupplemental Coolant Additives (SCA)at any time the additive goes below therecommended level. For extended lifecoolant mixture, this means an extenderpackage added halfway through thecoolant lifetime.

Regular Coolant Change IntervalCoolant SCA level must be tested atleast twice per year or whenever coolantloss occurs. For maximum coolantsystem efficiency, test the system atevery engine oil change interval, every1,000 hours or every 6 months(whichever comes first).

WARNINGHot engine. Keep clear of all hot engineparts and fluids. A hot engine and fluidscan cause serious burns.

Regular Coolant Filter ChangeIntervalsThe charged coolant filter contains 8units of SCA that are released slowly

over time to maintain the recommendedlevel during operation. Consult engineservice manual for proper SCA level andchange intervals.

CAUTIONExtended life coolant will test as out ofadditives (SCA), but SCA should not beadded. Shortened engine life may be theresult of adding SCA.

NOTEDO NOT add supplement coolantadditives (SCA) to extended life coolant.

Should the extended life coolant systembecome contaminated with regularcoolant exceeding 10% of the systemstotal capacity or if SCA is added toextended life coolant, drain the systemand refill with new extended life coolantor regular coolant.

CAUTIONDO NOT use a filter that contains SCA.Damage to components can result.



FUEL SYSTEM

DANGERA diesel engine will operate on any fuelwhich enters the cylinder, whether it isfrom the injectors or from the air intakesystem. Therefore, if any solvent is usedto clean out the air cleaner element, theengine may over speed during start-up.Engine damage, severe personal injury ordeath from burns or explosion may occur.

DANGERDO NOT mix gasoline or alcohol withdiesel oil fuel. This mixture can cause anexplosion and result in severe personalinjury or death.

DANGERDO NOT remove the fuel tank cap near anopen flame. Diesel fumes are combustibleand can cause an explosion or fireresulting in severe personal injury ordeath.

WARNINGIf a fuel leak is detected, stop the engineimmediately. The vapors from hot fuel arehighly flammable which may result in afire.

WARNINGDO NOT store fuel containers in thevehicle. They may leak, explode andcause or feed a fire. Empty or full, theypresent a hazard that may lead to burns inthe event of a fire.

Diesel Fuel Specification

CAUTIONDiesel engines for 2007 and later modelyear vehicles are designed to operate onlywith Ultra Low Sulfur Diesel (ULSD) fuel.Use of fuel other than ULSD will reducethe efficiency and durability of the engine,permanently damage the advancedemission control systems, reduce fueleconomy and possibly prevent the enginefrom running at all. Manufacturerswarranties are likely to be rendered voidby usage of improper or incorrect fuel,and usage of fuels other than ULSD fuel indiesel-powered vehicles is illegal andpunishable with civil penalties. Use of fueladditives to compensate for the lowersulfur content is NOT recommended.

QualityThe proper selection of fuel is essentialfor good economy, performance andengine life. No. 2D ULSD should beused when climatic conditions permit.No. 1D ULSD can be used during coldweather conditions. Blends of No. 1D

and No. 2D ULSD fuels can be used tosuit various climatic conditions.

NOTEThe use of lighter fuels (grade No. 1-D)can reduce fuel economy

Fuel Sulfur ContentFuel sold for use in diesel-poweredengines for 2007 and later model yearvehicles may only contain a maximumsulfur content of 0.0015% by weight.This was done to reduce particleemissions in the exhaust

NOTEThe use of ultra-low sulfur diesel fuel doesnot permit extension of engine oil changeintervals or oil filter changes.

Cetane NumberDirect injected diesel engines require aminimum cetane number of 43 undernormal starting conditions. Fuel with ahigher cetane value may be required forhigh-altitude or cold-weather operation.

FiltrationFuel should be clean and free ofcontamination. Clean fuels should haveno more than 0.05% of sediment andwater.



FUEL SYSTEM

Fuel AdditivesFuel additives are generally notrecommended or needed for fuels listedearlier. Cetane improvers can be used asnecessary. Biocides may be needed toeliminate microorganism growth instorage tanks. In cold conditions,treatment for water in the vehicle tanksmay also be necessary.

Consult your fuel supplier about the useof additives to prevent incompatibilityamong additives already in the fuel andthe additives to be used.

Supplemental Fuel EnhancersThere are many aftermarket productsavailable today which are intended to beadded by the customer. They generallyincrease operating cost withoutproviding benefits. Included are a varietyof independently marketed productswhich claim to be:• Cetane improvers• Emission control additives• Detergents• Combustion improvers• Smoke suppressants• Cold weather flow improvers

CAUTIONSupplemental additives are notrecommended because of a high risk ofinjection system problems or enginedamage.

NOTERepair expenses resulting frommalfunctions in the fuel system or withengine components when fuel enhancershave been used are not covered underwarranty.

Some fuel additives may be usedtemporarily, but they do not replacegood fuel handling practices. Theseproducts can be used:• Isopropyl Alcohol Use 1/2 liter per 450liters (1 pint per 125 gallons) of fuel forwinter freeze-up protection.• Biocide For treatment of microbegrowth or black slime. Followmanufacturers instruction for treatment.

Prohibited AdditivesThe following additives are specificallyNOT allowed and must NOT be mixed inwith the vehicle diesel fuel:• Gasoline: Adding gasoline to dieselfuel will reduce the cetane number andincrease combustion temperature. If atank contains a diesel fuel/gasolinemixture, it should be drained andcleaned as soon as possible.• Used Lubricating Oil: Mack Trucksdoes not recommend the use of anytype of used lubricating oil as anextender in the diesel fuel. Usedlubrication oil contains solids and acidsfrom the combustion process that canseverely corrode parts of the injection

system, resulting in reduced power andhigher maintenance cost over time.

Alternative FuelsAlternative fuels can be of severaldifferent types. There are vegetablebased fuels, aviation fuel and recycledpetroleum based fuels that are used incombustion engines. These are ingeneral not compatible with modernheavy-duty over-the-road dieselengines.

The use of unauthorized fuels maycompromise the levels of pollutants inthe exhaust to the point where theengine does not meet the emissionrequirements. This would make thevehicle illegal to drive on public roads.DO NOT use any kind of alternative fuelunless specifically authorized by MackTrucks.

Fuel StorageIf fuel is stored on site:

• Keep storage tank covered toprevent water entry.

• DO NOT use a tank made ofgalvanized metal or any galvanizedpiping for diesel oil storage. Dieselwill react with the zinc, formingsolids that can clog fuel filters andcause engine damage.



FUEL SYSTEM

• Fuel stored for a long time mayoxidize and form solids, causingfiltering problems.

• Keep the area around the fill capclean.

Generally, fuel contamination occurs asthe result of improper fuel handling. Themost common types of contaminationare water, dirt and microbial growth(black slime). The formation of varnishesand gums resulting from poor fuelstability or long storage (stale fuel) alsoaffects fuel quality. The best treatmentfor contamination is prevention bymaintaining a clean storage system andchoosing a reputable fuel supplier.

Fuel FiltersA primary fuel filter can be located onthe engine or remote mounted on theframe rail. This filter consists of a filtercartridge, a water separation bowl andmay have a fuel heater built in.

The secondary fuel filter is located onthe cold side of the engine, below theengine electronic control unit (EECU).The filter is a spin-on filter.

Mack MP engines utilize a spin-onprimary and secondary fuel filter. Bothfilters are located on the cold side of theengine

1 Secondary Fuel Filter

2 Primary Fuel Filter

The primary fuel filter on Mack MPengines incorporates a plastic waterseparator bowl. Additionally, the plasticbowl includes a water-in-fuel sensor. Awarning lamp on the instrument panelilluminates when water is detected in thefuel.

NOTEThere are optional fuel filter systems (suchas Davco, Conmet, etc.) available forMack MP engines. These fuel filtersystems use a single remote-mountedfilter, eliminating the spin-on primary andsecondary filters. For service informationconcerning these filters, refer to thespecific fuel filter manufacturers serviceliterature.



FUEL SYSTEM

Fuel/Water Separator(Engine Mounted)A warning lamp on the instrument panelilluminates when water is detected in thefuel. When the lamp illuminates, drainthe water from the separator by openingthe drain valve and allowing the water todrain from the bowl into a suitablecontainer. When fuel begins to drain,close the valve and tighten to 0.655 Nm(5 in-lb). Dispose of the drained water/fuel in an environmentally safe manner.

1 Water Separator Drain Valve

NOTEDO NOT drain the water separator bowlwhile the engine is running.

NOTEDrain the filter water trap daily. Changethe fuel filters at every oil change.

Fuel / Water Separator (ChassisMounted)Water and large contaminants fall to thebottom of the body and can be drainedaway. Dispose of the drained water/fuelin an environmentally safe manner.

NOTEDO NOT drain the water separator bowlwhile the engine is running.

NOTEDrain the filter water trap daily. Changethe fuel / water separator filter at every oilchange or when the fuel reaches the topof the filter.

1 Drain Valve

ELEMAX® Filter“SEEING IS BELIEVING”®

The patented clear cover allows the userto know when to change the filter. Fuellevel rises as the filter media becomes

contaminated, the fuel filter doesn’tneed replacement until fuel level is at theTop of the filter.

Fuel Tank Ventilation FilterSome vehicles are equipped with a fueltank ventilation filter. The purpose of thiscomponent is to filter out contaminantsthat can enter the fuel tank from the ventlines.

This filter should be replaced inconjunction with the vehicle air filter,when indicated by the air restrictiongauge or the air filter restrictor indicatorlight in the instrument cluster.

The maximum time allowed beforereplacement is 24 months.

For non-severe environments a vehiclewill have a frame-rail mounted filter.



FUEL SYSTEM



TIRES, WHEELS AND HUB

Tires

DANGERDO NOT attempt to repair wheels or tiresunless you are trained and equipped to doso. Wheel and tire assemblies cannot beworked on without proper tools andequipment. Failure to follow this may leadto serious personal injury or death.

DANGERDO NOT install regrooved, retreaded orrepaired tires on the steering axle(s). Theycould fail unexpectedly and cause the lossof vehicle control, leading to seriouspersonal injury or death.

DANGERDO NOT use mismatched tires on thesame axle. Always use the same type(radial or bias ply) or size. Mixing tires onthe same axle will affect the roadholdingand can lead to an accident, and seriouspersonal injury or death.

DANGERTires used on multi-piece rims must beassembled and inflated only byexperienced, qualified personnel. Tiresmust be inflated in a safety cagewhenever possible. If, however, a safetycage is not available, use a portable lock-ring guard. The tire must be deflated priorto removal of the tire-and-rim assemblyfrom the vehicle. Remove the valve core toensure complete deflation.

DANGERNEVER position your body in front of therim during inflation.

DANGERDO NOT install tires with a load rating thatis less than stated on the CertificationLabel in the door frame. The tire could beunintentionally overloaded, leading to anaccident, causing serious personal injuryor death.

WARNINGUNDER NO CIRCUMSTANCES shouldyou drive on underinflated or overloadedtires. A tire in this condition builds upexcessive heat which can result in suddentire destruction, property damage andpersonal injury.

CAUTIONNEVER use water-based sealants,puncture proofing, or liquid balancematerials containing water in All-SteelRadial Ply truck tires.

CAUTIONNever bleed air from your tires in anattempt to gain traction for a vehicle stuckin snow, ice or mud. This practiceprovides no additional traction andtypically results in under inflated tires.Never bleed air from a hot tire since thattire will then be under inflated.

Inflation PressureTo ensure maximum mileage and overallperformance from your tires, it isessential that they operate at the correctinflation pressure for the load carried.Check inflation pressure daily while thetires are cold. Always use an accuratetire pressure gauge. Refer to the specifictire manufacturer's information, or to thevehicle certification label for a completelisting of tire inflation pressures.

To adjust for pressure fluctuationsinduced by temperature changesassociated with winter weather, checkinflation pressure daily when the tires arecold (i.e., before the vehicle is driven).




InspectionInspect your tires daily. Look for bulges,cracks, cuts, penetrations and/or oilcontamination. Also, check for unevenwear. If damage is found, have aqualified mechanic thoroughly inspectthe tires, front end components andalignment. Replace or discard anydamaged tires or components.

Tire Manufacturer InformationMore detailed information can beobtained by referring to each tiremanufacturer's documentation.Documentation can be obtained eitherfrom the Internet or directly from themanufacturer.

Technical data provided includes:

• High-speed or low-speed ratings

• Repair, retreading and regrooving

• Use of tire chains

• Mixing radial and bias tires on thesame vehicle

• Tire mounting/dismounting

Oil Contamination of TiresLubricating oils, fuel oil, gasoline andother petroleum derivatives, can softenthe rubber and destroy the tire.Preventive maintenance is necessary toensure that oil leakage does not occur.Inspect the following areas on a regularbasis:

• Axle end seals

• Engine seals

• Transmission seals

• Drive axle seals

• Oil filters

• Oil and hydraulic lines (if equipped)

Refer to specific tire manufacturer'sbooks, or to the vehicle certificationlabel, for additional informationconcerning tires and their care.

Wheels

DANGERDO NOT use oil or grease on studs ornuts. The tightening torque is affected andcan lead to incorrect clamping loadsbetween the rim and hub. This could leadto a loss of the wheel. Loss of vehiclecontrol and serious personal injury ordeath can occur.

DANGERBefore checking the wheels, set theparking brakes, place the transmission inneutral and chock the wheels. Failure todo so can result in unexpected vehiclemovement and can cause seriouspersonal injury or death.

DANGERDO NOT use mismatched wheelcomponents. If they do not exactly matchthe original design specifications, theymay cause failure or separation leading toblowout and an accident and personalinjury or death.

DANGERWheels must be serviced only by aqualified technician. DO NOT do this workyourself. Inflated tires on wheels containcompressed air and if suddenly released,do so with an explosive force, resulting inserious personal injury or death.

Check wheels for signs of rust streaksaround the wheel nuts. This indicateslooseness (steel rims). Inspect all typesof rims for cracks. Cracks can appear inmany places but typically radiate outfrom where a load is applied. Inspectclosely around wheelnuts, handholesand inside circumference.




Wheel Nut TighteningAfter the initial tightening, retighteningmust be made within the first 800 Km(500 miles). After the first retightening,only normal inspection of nut tightnessis needed.Check front and rear wheelnut tightness with a torque wrench. Alldisc wheels for Mack vehicles have atightening torque of 610 Nm (450 lb-ft).Tighten the nuts in the correctsequence. Inspect bolts and nuts forsigns of wear or cracks. Make sure thatthe bolts are not bent. This tighteningcheck is particularly important whenrims or brake drums are newly painted.Paint can flake off from these surfaces,causing the nuts to lose their grip andthe wheel to loosen.

DANGERFailure to properly torque-tighten thewheel nuts can result in the breakage ofwheel studs and the subsequent loss ofwheels. Loss of vehicle control andserious personal injury or death can occur.

1 1-10 Stud Wheel Nut Tightening Sequence

Tire Wear

WARNINGDO NOT operate the vehicle with under-inflated tires. Always keep your tiresinflated to the manufacturersrecommendation. Increased flexing in thetire sidewall produces heat. The heat canbuild to the point of blowing the tire outcausing an accident.

WARNINGCheck tire pressure when the tire is cold.Never bleed the air from hot tires.Increased tire pressure measured in a hottire is normal. Low pressures may causeside wall flexing, resulting in increasedheat, leading to tire failure and vehicleaccident.

Remove stones lodged in ribs or inbetween double-mounted wheels.Check the tire pressure and leak-test thevalve stems.




1 Valve Stem

Measure the tread depth. The depthshould not be less than 3.2 mm (4/32-in)on front tires and not less than 1.6 mm(2/32-in) on drive tires.

Most premium steer tires start with 14.2mm (18/32-in) tread depth when new.Usually remove steer tires at 3.2 mm(4/32-in). Drive tires should be removedat not less than 1.6 mm (2/32-in).

It is important to have the wheelscorrectly aligned. Check for uneven tirewear frequently. Uneven tire wear is asign of wheels out of alignment.

Tire HintsHints on How to Avoid Unnecessary TireWear• Maintain correct tire pressure• Check the tire pressure when the tiresare cold• Check that valve caps are not missing• Keep the wheels balanced• Tire wear increases with speed

• Overloading not only decreases tire lifebut also creates a hazard• Incorrect front end alignment causesincreased wear

Dual mounted wheels should always beof the same type and diameter(maximum diameter difference allowedis 6 mm (1/4 in).

Hubs

NOTEHub maintenance should be performed bya certified technician.

Front Wheel Hubs

DANGERFailure to keep wheel bearings properlyadjusted and lubricated may result inaccelerated tire wear, poor handling and,in extreme cases, wheel separation fromthe hub or from the spindle resulting inloss of vehicle control and seriouspersonal injury or death.

Front Wheel HubsThe front wheel hubs can be filled withone of several types of oil. Motor oilshould be SAE 30 or 15W40. The oil canbe either petroleum based or synthetic.Axle oil, API GL-5, SAE 75W-90, canalso be used. There are no set change

intervals for hub lubrication. The onlyrequirement is that if the hub is opened,the lubricant must be changed.

Unitized Front HubsThe non-tapered axle hubs are sealedwith lubricant inside the hub.




Semi-Fluid Grease Pre-Set HubFor vehicles with the semi-fluid greasehub, inspect the hub annually or every161 000 Km (100,000 miles).

1 Semi-Fluid Grease Hub Cap

2 Hub Refill Plug

Tapered Axle EndThe tapered axle hubs do requirelubrication.



DRIVESHAFT LUBRICATION

Meritor has developed the Arvin MeritorExtended Lube (MXL) driveshaft series.

Old New17N (RN) 17X (MXL)

176N (RN) 176X (MXL)

18N (RN) 18X (MXL)

VehicleLines

Intervals

Linehaul From 80 500 km to 161 000km (50,000 miles to 100,000miles)

On-Highway

From 25 750 km to 161 000km (16,000 miles to 100,000miles)

GeneralService(City)

From 10 460 km to 40 250km (6,500 miles to 25,000miles)

On/Off Hwy(Construction)

As recommended(unchanged versus RN series)



ENGINE AIR FILTER

NOTEFor recomended intervals, refer to EngineMaintence Tables in the Engine section ofthis manual.

The air cleaner prevents dust, dirt andother harmful contaminants fromentering the engine through the airintake system. Maximum engineprotection can only be achieved throughregularly scheduled maintenancepractices that include periodic air intakesystem inspections and air filter elementchanges.

The most efficient method ofdetermining air filter element changeintervals is by regularly checking the airfilter restriction gauge, which may eitherbe mounted directly to the air cleanercanister, on the air cleaner outlet tube orinside the cab. The restriction gaugemeasures the amount of restriction inthe air filter element. Some chassis mayhave a dash-mounted dial-typerestriction gauge which measures filterrestriction in mm/inches of water.

Change the air filter element inaccordance with the procedures asoutlined, or the dash-mounted gaugeindicates inlet restriction as follows:

Mounted Gauge InletRestrication IndicationEngine Milimeters (Inches) Water/KPaMP7™ 510 (20) /5 kPa

1 Air Filter Restriction Gauge

Damage to the air filter element, such asholes in the filter media, will give aninaccurate restriction reading. Therefore,even if a maximum restriction is notindicated, the air filter element should bechanged yearly or at recommendedintervals, as described in this manual.

When replacing the air filter element, orwhenever the air inlet system has beendisassembled, inspect the inlet air ductsbetween the air cleaner canister outletand the turbocharger inlet as follows:• Inspect the rubber elbows for cracks,splitting and/or holes. Rubbercomponents must be flexible so thatthey conform to the plastic ducts andensure a tight seal.

• Inspect plastic ducts for cracks and/orholes.• Ensure that all hose clamps areproperly installed and tightened tospecifications.• Make sure the plastic ducts do not rubagainst any components such as airconditioning hoses, wire harnesses, etc.

Filter Element Installation

1 Wipe the air cleaner housing clean.

2 Remove the filter element(s).

3 Inspect sealing areas for dirt trackswhich would indicate that dust hasleaked past the seal. If dirt tracks arefound, the cause must bedetermined and corrected.

4 Thoroughly clean the inside of the aircleaner canister with a damp cloth orvacuum cleaner.

5 Inspect the sealing areas of thehousing for damage. Repair orreplace as necessary.

6 If equipped with a metal canister,inspect inside the canister for rust. Ifrust is present:

1 Remove the air cleaner canisterfrom the chassis.2 Remove all loose rust with a wirebrush or a coarse Scotch Brite pad.



ENGINE AIR FILTER

3 Sand with 180/240 grit wet or drysand paper.4 Thoroughly wash the area withPPG DX-440, DX-436, DX-437 waxand grease remover or equivalent,and wipe dry.5 Prime immediately with PPGDEP-351 epoxy primer.6 Reinstall the air cleaner canister.

7 Use Mack-approved replacementelements and gaskets. Make surethe new elements and gaskets arenot damaged. Be sure to use newgaskets each time the element ischanged. Install the cover and,depending upon cover configuration,tighten as follows:• Air cleaner with large wing nut incenter of cover; hand-tighten wingnut.• Air cleaner with three thumbscrews around outer edge of cover;hand-tighten thumb screws.• Air cleaner with retaining nutsaround outer edge of cover; tightenretaining nuts between 11 – 14 Nm(8 – 10 ft-lb).

NOTEDO NOT attempt to clean the air filterelement with compressed air, as this coulddamage the filter media and possiblyresult in severe engine damage.



AIR SUSPENSIONS

The following maintenance items shouldbe performed on all air suspensions:

Preventive Maintenance• Visual Inspection: Inspect allsuspension components, checking forsigns of wear, damage or unwantedmovement. Look for bent or crackedparts. Replace all worn or damagedcomponents as required.• Air Spring: Inspect for chafing or anysigns of spring or component damage.Ensure that the upper bead plate is tightagainst the underside of the frame.Check for lateral slippage at the lowerair spring bracket.• Support Beam Assembly: Inspect theoverall condition of the support beam fordents, dings or other damage. OnHendrickson PRIMAAX suspensions,check the D-pin bushings for tearing orextreme bulging. Check for metal-to-metal contact in the bushed joints.Replace worn or damaged componentsas required.• Frame Hanger Bracket: Inspect for anysigns of loosening or damage. OnHendrickson PRIMAAX suspension,check for loosening or damage at theQUIK-ALIGN connections or longitudinaltorque rod connections. Replace wornor damaged components as required.• Cross Beam: Inspect for cracks,damage, metal shavings or looseness atthe beam connections. Replace worn ordamaged components as required.

• Transverse Torque Rods: Inspect forsigns of looseness at the transversetorque rod connections. Check bushingsfor tearing or excessive bulging. Checkthe transverse torque rod for dents orbending. Replace worn or damagedcomponents as required.• Shock Absorbers: Inspect for signs ofdents or leaking (oil misting is notconsidered leakage). Replace worn ordamaged shocks as required.• Tire Wear: Inspect tires for wearpatterns that might indicate suspensiondamage or misalignment. Replace wornor damaged components as required.• Height Control Valve and Air Lines:Check for loose, bent or damaged parts.Check air lines for chafing or leaking.Check height control valve and air linesfor leakage. Replace worn or damagedcomponents as required.



STEERING AND BRAKES MAINTENANCE

Steering SystemExcessive play in the steering system ischecked by turning the steering wheelwhile the engine is stopped. With thefront wheels pointing straight ahead,turn the steering wheel until the frontwheels starts moving. Then, turn thesteering wheel the other way until thefront wheels move. Play should not bemore than 25 mm (1 in) at the rim of thesteering wheel. If the steering play isexcessive, check the steering linkage forlooseness, wear, etc. Make necessaryrepairs before driving the vehicle.

Power Steering FluidThe power steering fluid reservoir isfilled with Automatic Transmission Fluid(ATF) Dexron III. This fluid helps maintainthe health of the power steering system.If the fluid has darkened, it indicates thatthe power steering system is runninghotter than normal and the fluid isoverheating. If this symptom is noticed,take the vehicle to a dealer fortroubleshooting and have the fluidchanged.

Checking Power Steering FluidProper fluid level should be between thelines on the dipstick.

NOTECHECK COLD

1 Maximum Level

2 Minimum Level

Brake System

DANGERDO NOT use replacement parts anywherein the brake system unless it conformsexactly to original specifications. Anonconforming part in your vehicles brakesystem could cause a malfunction, leadingto loss of control of the vehicle resulting insevere personal injury or death.

DANGERDO NOT release the parking brake orattempt to move the vehicle until brake airpressure in both circuits is at least 100 psi(690 kPa). Failure to follow this proceduremay lead to uncontrolled vehiclemovement and cause severe personalinjury or death.

Air Brake SystemThis chassis features a dual brakingsystem which has two complete aircircuits: a primary circuit for rear brakesand a secondary circuit for front brakes.Each circuit receives air from separatereservoirs. Although there are two aircircuits, they operate as one brakesystem through the dual-circuit treadlevalve. This provides the driver with easy,graduated control when applying andreleasing the brakes.

The air pressure in the two circuits ismonitored by gauges on the instrument




panel. When air pressure drops below517 ± 34 kPa (75 ± 5 psi) in eithersystem at any time other than vehiclestartup, pull to the side of the road anddetermine the problem. If air pressurecontinues to drop below 55 ± 5 psi inBOTH systems, the Low Air PressureWarning indicator and buzzer will beactivated if low air pressure occurs ineither circuit.

In tractor applications, the Trailer SupplyValve (red octagonal knob) willimmediately pop out in the event of atrailer breakaway or sudden trailer airline failure, which will apply the trailerspring brakes. In the event of a slow leakin the trailer air system, the trailer supplyvalve will pop out when system Pressurereaches 70 psi. This protects the tractorair system from further pressure loss.

The air brake system consists of threemain elements:

• The compressor, governor andreservoirs supply and store the airpressure.

• The brake application valve controlsthe brake application pressures.

• The brake chambers control thebrake mechanism.

Air Brake Operation

CAUTIONAvoid sudden stops. Constant, suddenstops may negatively affect theperformance of braking and driving parts.

When slowing for a stop, leave theclutch engaged for as long as possibleto use the braking effect of the engine.When forward speed has dropped to alittle above idling speed, push clutchpedal in and brake to a complete stop.

Automatic Slack Adjuster

DANGERAutomatic slack adjusters MUST NOT bemanually adjusted in an effort to correctexcessive push rod stroke, as thiscondition indicates that a problem existswith the automatic adjuster, installation ofthe automatic slack adjuster or problemsrelated to components of the foundationbrakes. These conditions will not becorrected by manually adjusting theautomatic slack adjusters. Manualadjustment of automatic slack adjusters isa dangerous practice that could result inserious consequences. This practice givesthe vehicle operator a false sense ofsecurity about the effectiveness of thebrakes, and the brakes will likely soon beout of adjustment again.

Automatic slack adjusters are designedto automatically maintain proper brakechamber pushrod travel andcompensate for brake lining wear duringnormal use. Manual adjustment of anautomatic slack adjuster should neverbe performed except when performingbrake or wheel service (such as backingoff the brake shoes for wheel removal,brake shoe relining/replacement, brakedrum reconditioning, etc.).

When pushrod travel exceedsspecifications (as given in the "BRAKEADJUSTMENT" section of theMaintenance and Lubrication Manual,




on a vehicle equipped with automaticslack adjusters, a mechanical problemwith the slack adjuster, brakecomponents or improper installation ofthe slack adjuster is indicated. If brakesare found to be out of adjustment, thevehicle must be taken to the nearestrepair facility to have the probleminvestigated and corrected.

NOTEThe brake system is a critical vehiclesafety system. For your safety and forthose around you, follow therecommended preventive maintenancechecks. If any problems occur, have theminvestigated immediately by an authorizedservice facility

Brake System Maintenance

1 Block the wheels to prevent thevehicle from moving.

2 Start the engine and build air systempressure to governor cutout.

3 Stop the engine.

4 Release the parking brakes.

5 Apply and hold the Service Brake.

6 Have an assistant check for properresults by observing the movementof the slack adjusters as indicatedbelow:

• The brakes on both the steeringaxle or the rear drive axle(s)should always apply as indicatedby movement of the slackadjuster.

• Check for air leakage.

7 Set park brake when done.

Air Tanks

DANGERDrain the air system tanks at therecommended intervals. If condensationaccumulates, moisture can enter thebrake system air valves, causing corrosionor clogging. The safety of the brakesystem could be compromised, leading toan accident causing severe personal injuryor death.

WARNINGWhen draining the air tanks, DO NOT lookinto the area of the draining air. Dirt orsludge particles may be in the air streamthat could cause eye injury.

Air tanks should be drained daily. Makesure the drain cocks close properly afterdraining. Empty moisture from air tanksby pulling the drain valve lanyard or pullcord. The tanks should be checked forcondensation fluid, even if an automaticdrain valve is installed.

It is very important that the air system iskept clean. If sludge or oil is found in thedrainage or an excessive amount of fluidis drained out of the tanks see yourauthorized dealer.




Air DryersAir dryers utilize an oil coalescingdesiccant cartridge which removesatomized oil and other particulate matterfrom the air system. The oil coalescingdesiccant cartridge must be changedyearly.



CHASSIS MAINTENANCE

SpringsThe spring package is fastened to theaxle beam with U-bolts. It is importantthat the U-bolt nuts are properlytightened. The nuts may loosen up withtime. Severe service will loosen themfaster. Loose U-bolts can cause springsto break, axle misalignment, hardsteering and abnormal tire wear. Inspectthe chassis for broken springs, shocks,loose or broken axle U-bolts. If any ofthese are found, contact your localMack dealer.

Spring BushingsWhen lubricating the springs, lift the axleoff of the floor, suspend the frame withaxle stands and lower the axle. Thespring bushings are now in the positionwhere grease can be added to thecontact surfaces. If the spring bushingsare greased without taking the load off,high wear and lower lifetime will occurbecause grease is not able to reach thecontact surfaces. If the vehicle is for

severe service applications, increase thefrequency of spring bushing lubrication.

Rubber BushingsRubber bushings are used for extendedservice life. If your vehicle is equippedwith rubber bushings DO NOT lubricatethem. Replace the leaf spring if it isdamaged or has premature or excessivewear.



CAB MAINTENANCE

DoorsThe door lock mechanism should begreased annually using white grease.Lubricate the door lock cylinder withliquid graphite annually, or more often inclimates with a lot of snow and salt onthe roads. On wet and salted roads,road spray can enter the door lock keycylinder. Lubricate the cylinder withliquid graphite annually or more often ifnecessary. The door hinge pins aretreated at manufacturing and thensealed. No lubrication is necessary. Tokeep the door rubber moldings andseals around the windows in goodworking order and to prevent them fromfreezing shut during the cold season,occasionally spray on a siliconecompound.

1 Door Lock Mechanism

Rust ProtectionThe rust protection applied when thecab was produced is adequate fornormal use and service. If an extension

of the cab rust protection is desired or ifthe vehicle is used in a severeapplication, it is recommended thatcavity wax is re-applied every 3rd year.



LUBRICATION

Chassis LubricationGeneral lubrication includes lubricatingall the grease fittings in the drivetrain,front and rear suspensions, powersteering, and front axle, using a greasegun.

Grease the chassis every 24 000 km(15,000 mi). However, the lubricationintervals should be every 16 000 km(10,000 mi) or less to reflect heavy-dutyuse if the vehicle is in a demandingenvironment or running in a dirty orcorrosive atmosphere.

Lubricating GreaseUse grease with a lithium base with EPadditives and a consistency of NLGI No.2. Care should be taken not to use anygrease other than one with EP additivesfor the driveshaft. DO NOT use any solidlubricants, such as graphite, copper ormolybdenum disulfide.

Lubrication ProcedureMake sure the grease fittings arecleaned off before greasing fill grease tothe point where old grease andcontaminants are forced out from the

part and only new grease comes out. Ifnew grease cannot be filled so oldgrease is flushed out, the part needs tobe checked for problems. If a fittingdoes not accept lubrication due todamage or internal stoppage, replace it.

NOTEThink of greasing the same way as an oilchange. All old grease should come outand be replaced with new grease. Removeexcess grease from fittings, shackles andother surfaces.



LUBRICATION



LUBRICATION

Lubrication Notes

1 Spring HangerUse a lithium based grease withspecification API NLGI No. 2. Whenlubricating the left and right sides ofthe front springs, lift the axle off ofthe floor, suspend the frame withaxle stands and lower the axle.Thespring bushings are now in theposition where grease can be addedto the contact surfaces.

NOTEThe rock guard will have to be removed (ifequipped).

NOTEAlways grease a Mack front axle with thewheels on the ground.

NOTETo grease non-Mack axles, they aretypically greased with the wheels on theground. Consult with the axlemanufacturer for the latestrecommendation.

2 Slack AdjusterDo not grease till 1st scheduledmaintenance interval.

NOTESee Manufactures Specifications forspecific grease. Adjust according to thespecific slack adjuster manufacturingspecifications.

2A Brake Cam

NOTEIf the brake cam seal does not purge,make sure the inner seal does not purgeinto the brake drum and onto the brakelinings.

3 Steering GearUse a lithium based grease withspecification API NLGI No. 2. Onlyuse a hand operated grease gun.The high pressure from an airoperated grease gun will damage theseal.

4 Draglink and Steering ShaftUse a lithium based grease withspecification API NLGI No. 2.

5 Kingpin, Upper and LowerUse a lithium based grease withspecification API NLGI No. 2.

NOTEAlways grease a Mack front axle with thewheels on the ground.

NOTETo grease non-Mack axles, they aretypically greased with the wheels on theground. Consult with the axlemanufacturer for the latestrecommendation.

6 Tie-RodUse a lithium based grease withspecification API NLGI No. 2.

NOTEMack axles may use a greased-for-life tie-rod. No provisions for adding grease areavailable.

7 Leaf SpringsFront and rear leaf spring eye pins,should be pressure lubricated withchassis grease. Vehicles equippedwith multi leaf springs should alsohave, the leaves lubricated with aspray gun or brush using a rustinhibiting oil.

CAUTIONKeep grease and oil, off of rubberbushings. Failure to do so will result incomponent damage.



LUBRICATION

NOTEIf the vehicle is operated in sandy or dustyenvironments, the spring ends should beleft dry. Dirt and grease can mix, resultingin a "sandpaper" action that may causepre-mature wear to the spring ends.

8 Clutch ReservoirCheck the fluid level in the reservoir.Add brake fluid if necessary. Useonly DOT 4 brake fluid in the clutchrelease system. Mixing DOT 4 brakefluid with petroleum based oil willcause seal damage which will causeleakage.

9 Clutch Bearing LinkageUse a lithium based grease with EPadditives to specification API NLGINo. 2.

NOTEInspection cover removal is necessary.Lubricate according to Eaton's lubricationdocument and reinstall the inspectioncover. See http://www.roadranger.com forthe latest heavy-duty clutch serviceinformation.

10 U-JointsUse a lithium based grease with EPadditives to specification API NLGINo. 2.

NOTEEnsure that grease purges out of all fourseals of the U-joints.

11 PTO/Hydraulic ReservoirWhen lubricating the spring pinbusing use a lithium based greasewith specification API NLGI No. 2.

12 Rear Suspension (48k-70ksuspension)

NOTENewer versions may have rubber bushingthat do not need lubrication.

NOTEEarlier versions of the T-Ride and B-Ridespring cradle required lubrication.

13 Coolant LevelAdd coolant if necessary. Only usepre-mixed clean water and antifreezein a 50/50 mix.

Add only the same type antifreeze,that is: extended life or standard.

14 Steering Assist CylinderUse a lithium based grease with EPadditives to specification API NLGINo. 2 to grease both ball joints.

15 Front Oil Lubricated WheelBearingsThere is no set change interval.Change the oil (or grease) only inconnection with work on the hub or ifdirt is found in the lubrication. Usemotor oil SAE 30. Lubricate both theright and the left wheel bearings.

16 Power Steering FluidCheck the fluid in the reservoir withthe dipstick. Add oil if necessary.Use ATF Dexron® III or better.Change fluid every 150,000 miles(240,000 km). Change filter everyyear.

17 Engine Oil and FilterFor oil change schedule see ServiceInformation in Group 175-60.

18 Windshield Washer FluidLevel

19 Automatic / ManualTransmission

Automatic TransmissionSee the Manufacturer's Operator'smanual for intervals and quantity. ForAllison transmissions please refer toAllison transmission for the latestrecommended fluid andmaintenance interval.



LUBRICATION

Manual TransmissionUse a mineral or synthetic oil. Checkoil level periodically. Level should beto the bottom of the inspection hole.

20 Auxiliary Axle(s)If equipped with auxiliary steer, lift orsteerable lift axles use a lithiumbased grease with specification APINLGI No. 2.

Also, lubricate the Brake, Cams,Slack adjuster and Tie-rod ends.

21 Rear AxleCheck the oil level in the differentialby removing the fill/level plug in thehousing. The oil should be level withthe bottom of the fill/level plug hole.Add oil if necessary. The checkshould be performed parked on a flatlevel surface.

CAUTIONMost rear differentials have a large screwand nut protruding from the housing. Thescrew and nut hold the thrust plate shoeagainst the ring gear and are not to beconfused with the fill/level plug.

NOTERefer to Service information for Oil Typesand for Approved/Correct Oils.



HEADLAMP BULB REPLACEMENT

NOTEThis vehicle uses a sealed beam typeheadlamp bulb which is replaceablewithout special tools.

1 Headlamp Bezel

2 Headlamp Rim

3 Headlamp



WIPER BLADES

Vehicle Wiper BladesCheck wiper blades for any damage,"dead" rubber and attachment to arm.

Bolt-Arm ConnectorYour vehicle is equipped with a bolt styleconnector attachment where the armand blade meet. Remove the fastenerholding the blade to the arm. Replacewith a new unit.



VEHICLE CLEANING

Cab


Wash all exterior painted surfacesfrequently to remove dirt. It is especiallyimportant to wash off salt-laden snowand ice during the cold season. A milddetergent approved for automotivecleaning can be used but avoid strongdetergents.

NOTEDO NOT aim the water jet directly at doorand window seals or door locks.If locksare filled with water, use compressed airto clean the water out and then applyliquid graphite. Be especially careful ofleaving water in locks or around sealsduring freezing weather.

Apply a coat of wax regularly. This willhelp the paint and other surfaces keeptheir luster. If the surface gets dull, use arestoring cleaner specially designed forthis.Clean off all tar spots and tree sapbefore waxing.

ChassisKeep the chassis free from buildup ofdirt. Make sure the chassis is cleanedbefore the maintenance inspections tohelp spotting leaks, etc. As salt can bepart of the road sludge during the coldseason, remove buildup of snow and iceso it does not promote corrosion. At theend of the cold season, thoroughly flushaway all collected dirt from the chassis

If signs of delamination of the frame railare apparent, complete the followingsteps:

1 Clean chassis with high pressurewater spray. Use mild detergent ifavailable; remove loose dirt andgrease.

2 Continue high pressure wash toaffected delamination areas of paintfrom the frame rails. Apply highpressure spray until paint holds onframe substrates.

NOTEAfter completing these steps, to avoidfurther delamination, have the framerailserviced as soon as possible.

Stainless SteelStainless steel will rust if exposed to saltfor too long. Wash frequently, especiallyduring the cold season, to remove salt-

laden snow and ice. If rust appears,wash the surface and use a rubbingcompound to remove the rust. Apply acoat of wax as a finish (do not wax partsthat get hot, such as exhaust pipes,etc.).

NOTENever use steel wool to clean stainlesssteel. Pieces of the steel wool break offand can create rust stains on the surface.

ChromeChrome surfaces will rust if they are notcleaned and protected. This is especiallyimportant during the cold season whenroads are salted or in coastal areaswhere the salt level in the air is high.Clean chrome surfaces with clean water.If the surface has heavy dirt or tar spots,use a tar remover. To remove rust spots,use a non-abrasive chrome cleaner andapply a coat of wax as a finish (do notwax parts that get hot, such as exhaustpipes, etc.).

NOTENever use steel wool to clean chrome.Pieces of the steel wool break off and cancreate rust stains on the surface.

AluminumUnprotected aluminum surfaces willform an oxide layer if not maintained.



VEHICLE CLEANING

This is especially important during thecold season when roads are salted or incoastal areas where the salt level in theair is high. Clean with steam or highpressure water. Use a mild detergent ifthe dirt is heavy. Rinse well. Cleanaluminum surfaces with warm water. Ifthe surface has heavy dirt or tar spots,use a tar remover. To prevent spotting,wipe aluminum surfaces dry afterwashing.

UpholsteryClean vinyl and cloth upholstery withlight brushing or vacuuming. If heavilysoiled use a fabric stain remover.

PlasticThe plastic in the upholstery can becleaned with a soft cloth and mild soapsolution.



SEAT BELT MAINTENANCE

Clean and InspectKeep the belt dry. Clean with a mildsoap solution and lukewarm water.

Periodically inspect the following areasand replace any inadequate parts:

Buckle and Latchplate — The buckleand latchplate should mate easily with asolid click and release easily and quicklywith moderate pressure on the releasebutton. All metal seat belt componentsshould be free of signs of damage,corrosion or rust.

Webbing — The webbing should showno signs of wear, fraying or holes, and itshould be reasonably free of dirt whichcould find its way into the retractingmechanism.

Retractors — The retractors shouldfunction smoothly and maintain anappropriate amount of tension. Loosewebbing is an indicator thatmaintenance is needed; it's likely that atoo-loose belt will fail to tighten properlywhen necessary.

Seat Belt Mounting Components — Thetethering should be free of wear anddebris; the webbing should show nosigns of wear, fraying or holes; and themetal components should be free ofsigns of damage, corrosion or rust.



FRONT BUMPER / PLATE MOUNTING

CAUTIONDO NOT cover the opening in the frontbumper with a license plate. Covering thishole will restrict airflow to the lowerportion of the radiator. This can cause theengine to overheat, which can damage theengine.

1 Plate Mounting



METRIC CONVERSIONS

NOTEUse all tools on the fasteners they weremade to be used on. Use metric tools onSl metric units only. Never try to usemetric tools on U.S. standard fasteners orU.S. standard tools on Sl metric units.

CAUTIONPotential external/internal threadmismatch condition(s) may occur withcertain metric thread-inch thread fastenercombinations, and with fastenercombinations involving incompatiblemetric fastener systems. A given threadmismatch condition can result in threadstripping and/or assembly weaknessleading to potential service failure, therebyrendering a vehicle non-operational and/orunsafe for operation.



METRIC CONVERSIONS

Conversion ChartSI 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

0.3937 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


EMERGENCY ACTION

EMERGENCY ACTION

TOWING

Towing With the FrontSuspension Lifted

NOTEDuring towing, the main switch andparking lamps shall be lit if the electricalsystem of the vehicle is functioning.

NOTEDuring recovery, Do Not pull from frontaxle or damage to u-bolts clamp groupcould occur.

NOTEWhen the vehicle is towed with the frontsuspension lifted, the steering lock mustbe released.

CAUTIONWhen the driving wheels are still incontact with the ground the axle shaft(s),or prop shaft must always be removed inorder not to damage the transmission.

If the axle shafts have to be removed,the hubs must always be provided withtight fitting covers. Sand and dirt couldotherwise find their way in and causeconsiderable damage.

Disconnect the prop shaft from the rearaxle and fix it securely to the chassis, orremove the entire prop shaft.

1 Prop Shaft

ABS

NOTEDuring towing with the front suspensionlifted, a fault code for "abnormal sensorsignal front" is set in the ABS system. Thisshould be considered during the nextservice, when the ABS fault codes arechecked.

The fault code is deleted with theservice tool; please refer to the serviceinformation for the ABS system.

Towing with the RearSuspension

NOTEWhen the vehicle is towed with the rearsuspension lifted, the steering wheel mustbe locked with the steering locked.

This method is preferred when theproper equipment is not available toperform the wheel lift method and isnecessary for wreckers not equippedwith an under axle lift system.

NOTEIf roof deflectors cannot be removed, towfrom the front of vehicle only.


EMERGENCY ACTION

TOWING

UnloadingIf circumstances allow, unload thevehicle before lifting the rearsuspension.

The vehicle is unloaded to reduce theaxle loading on the towing vehicle, limitthe loading on the vehicle's lifting pointsto minimize the risk of damage to thetowing vehicle.

If it is not possible to unload the vehiclewhere it is, it can be towed a shortdistance to a suitable place whereunloading can take place.

Maximum Loading DuringLifting and TowingThis information specifies the loadingwhich can be applied when using atowing hook, towing hitch cross-member, axles and or torque stayanchorages.

Single Towing Hook: The hook must notbe loaded by more than the vehicle'sgross weight.

Double Towing Hooks: Each hook mustnot be loaded by more than half thevehicle's gross weight.

Towing Hitch, Towing Hitch Cross-Member: max. 200 mm (7.8 inches) fromcenter of member web

• Lengthways: 20 tons

• Vertically (lift): 7 tons

• Sideways: 17 tons

Axles, Front And Rear:

• Static loading, lengthways andvertically: 2 times axle loading

• Dynamic, e.g. during towing: 1 timesaxle loading

DANGERDo not use the tow eyes for raising thefront of the vehicle; the tow eyes canbreak. Do not crawl under a vehiclesuspended by tow eyes. Failure to followthese instructions can result in seriouspersonal injury or death.

NOTEThe towing hooks on the vehicle mustonly be used for towing.


EMERGENCY ACTION

TOWING

Lifting, GeneralVehicles must only be lifted by the liftingpoints specified below. Always usesuitable lifting devices, such as clevisesand chassis guards, to avoid damagingthe vehicle.

Lifting Vehicle with LeafSprings

Front SuspensionLift behind the front spring anchorage onthe chassis member, or beneath thefront axle.

Rear SuspensionLift underneath the towing hitch crossmember. If the vehicle does not have atowing hitch cross member, use thechassis ends for lifting.

CAUTIONRemember to always use a chassis guardwhen using a cross member for lifting.

1 Lifting Locations

Rear Suspension

Towing Configurations (Rear,Side, and Tow Hooks)

NOTEUse these methods for vehicle recoveryonly.

WARNINGThe steering does not have any servoeffect if the engine is not running.

Parking Brake and Towing HooksThe parking brake must be releasedduring towing.

Use the vehicle's towing hook(s) fortowing. If the truck is equipped with onetowing hook, this may have the grossweight of the truck applied from straight

in front. If the truck is equipped with twotowing hooks, each one of them mayhave half the gross weight of the truckapplied from straight in front.

WARNINGThe vehicle's towing hook(s) must only beused for towing. Incorrect use can lead topersonal injury if the towing hook isloaded with a greater weight than it isdesigned for.

Towing BackwardsTow from the rear spring anchorage ortrailer hitch hook.

1 Tow from rear spring anchorage or trailer hitchhook

Towing SidewaysWhen towing sideways, select anattachment point close to the axleanchorage, such as a spring or torquestay anchorage. In other cases, the


EMERGENCY ACTION

TOWING

chassis could be subjected to suchheavy loading that it could be bent.

1 Use a spring or torque stay anchorage

Releasing the Brakes

NOTESome trucks can have parking brakecylinders on two axles.

WARNINGAlways start by applying chocks to thewheels, so that the truck cannot roll away.This is important, since you have to lieunderneath the truck. If wheel chocks arenot applied, personal injury or death mayoccur.

Parking Brake MechanicalRelease (Drum Brakes)The parking brake can be releasedmechanically if compressed air is notavailable.

• Remove the cap on the end of theparking brake cylinder. Remove thet-bolt from the canister by looseningthe nut, and insert into the holematching the slots on canister to t-bolt. The bolt needs to be turned 1/4turn and then securely tighten thenut.

• Remember to remove the t-bolt andsecure in its original location, andput the protective cap back on theparking brake cylinder when towingis completed.

NOTEDo not remove the split pins from designswhich have a split pin. Instead unscrewthe screw and nut together.

1 Park Brake Release Screw


EMERGENCY ACTION

TOWING

Parking Brake MechanicalRelease (Disc Brakes)The brake cylinders have a releasemechanism for the parking brake spring,which means that the release bolt doesnot come out of the brake cylinder.

When you start to release the parkingbrake manually, a red plastic plug comesout of the center of the nut. It is entirelyout after three turns. A total of about 45turns are needed to fully compress theparking brake spring. When the parkingbrake is fully reinstated, (springreleased), the red plastic plug will returninto the center of the nut.

CAUTIONThe maximum torque for the releasemechanism nut is 47 Nm (34.67 ft-lbs).

NOTEAlways fill the parking brake tank with airwhen available, and release the parkingbrake, to reduce the amount of turningneeded on the release mechanism nut.The nut should only be released inexceptional cases, with no air in theparking brake section.

Plastic Plug for Release Mechanism


EMERGENCY ACTION

JUMP-STARTING ENGINE

Jump-Starting EngineIf you encounter a situation in which it isnecessary to jump-start an engine, usethe following procedures.

WARNINGBatteries which are to be linked togethermust be of the same voltage (12 to 12, 24to 24). Take care to observe properpolarity when connecting batteries.Batteries produce explosive gases. Keepsparks, flames, cigarettes, etc., away frombatteries at all times. Protect your eyes bywearing safety goggles. Be sure vehiclesare NOT touching each other.

WARNINGRemember that batteries contain ahydrogen and oxygen mixture, which ishighly explosive. A spark which couldoccur when you apply the jumper cablesincorrectly could be enough to cause thebattery to explode and injure you anddamage the truck. The battery containssulfuric acid, which can cause seriouschemical burns. If you get any acid in youreyes, skin or clothes - rinse with largequantities of water. If you get any splashesin your eyes, contact a doctor at once.

CAUTIONThe battery contains acid which iscorrosive and poisonous. It is thusimportant that the battery is handled in anenvironmentally compatible manner.


WARNINGBattery posts, terminals and relatedaccessories contain lead compounds,chemicals known to the state of Californiato cause cancer and reproductive harm.Wash hands after handling.

1 The ignition lock in both trucksshould be in position 0 (OFF).

2 Make sure that the battery systemvoltage of both truck (A) and truck(B) have the same votage. (A is 12volt and B is 12 volt). Ensure there isNO physical contact between trucks.

3

1 Positive Cable (Red)

2 Negative Cable (Black)

A - The truck which gives start helpB - The truck with a dead battery

4 Connect one clamp on the blackcable to the negative terminal ontruck A, (2) a large jump start nut.

5 Check that the clamps are securelyattached, so that no sparks occur.

CAUTIONDo not lean over the battery during thestart attempts, to avoid the possibility ofpersonal injury.

6 Start the engine in truck A. Allow theengine to run for approximately twominutes, at 1000 rpm, to ensure thatadequate charge for a preheaterequipped truck has been transferredto the weak batteries.


EMERGENCY ACTION

JUMP-STARTING ENGINE

7 Start the engine in truck B.

8 Remove the cables in the reverseorder from attachment.


INDEX

A

ABS ............................................ 80, 128Accessory Power Outlets ................... 94Advisory Labels on Chassis ................. 9Aftertreatment .................................... 80Air Conditioner ................................... 83Air Dryers ......................................... 196Air Filter .............................................. 81Air Horn .............................................. 93Air Pressure ........................................ 80Air Suspensions ............................... 192Air Tanks ........................................... 195Air temperature ................................ 108Allison Automatic Transmissions ..... 115Allison Transmission Fluid ................ 106Alternative Fuels ...................... 101, 180AM-FM-WX Radio ............................ 133Anti-Lock Brake System (ABS) ........ 214Anti-Lock Brake System .................... 80Anti-lock Braking System ................ 128ATC ..................................................... 80Automatic Belt Tensioner ................. 173Axles ................................................ 108

B

B10 Biodiesel ................................... 101Batteries ........................................... 164Battery Rating .................................. 164Battery Warmer ................................ 164Belt Wear .......................................... 171Blower Control Knob .......................... 83Bluetooth® ....................................... 136Brake System ................................... 193

Brakes .............................................. 108Breaking In a New Vehicle ................... 4

C

Cab Maintenance ............................. 198Cab Tilt ......................................... 84, 85California Emission ControlWarranty Statement ........................... 14CD Player, iPod, USB, Auxiliary ....... 135Charge Air Cooler ............................. 170Charging ........................................... 164Chassis Lubrication ......................... 199Chassis Maintenance ....................... 197Checking Oil Level ........................... 160Clean Idle Engines ............................... 5Clock, Alarm ..................................... 134Cold Check ...................................... 122Coolant Change Interval .................. 178Coolant Temperature ......................... 77Coolant ............................................. 176Cooling System ................................ 175

D

Daily Maintenance Service Charts ... 146Daily Maintenance ............................ 153DEF .................................................... 80Dial Menu ......................................... 137Diesel Fuel Specification .................. 179Differential Locks ............................. 110Disc Brakes ...................................... 218Discharged Batteries ........................ 164Dome Light ......................................... 93Door Lubrication .............................. 198Door ................................................... 70

Downshift Schedule ......................... 117Downshifting .................................... 117DPF .............................................. 80, 81Drain Plug ........................................ 126Drive Axle ......................................... 110Drive Belt Installation ....................... 173Drive Belt Replacement Intervals ..... 171Drive Belt Routing ............................ 173Driveshaft Lubrication ...................... 189Driveshaft RN to MXL ...................... 189

E

Electric and Electronic Systems ...... 165Electrical Protection ......................... 166Electrical System ............................. 164ELEMAX® Filter ............................... 182Emission Green House GasComponent Warranty ......................... 17Emission Warranty Certificate ............ 33Engine Air Filter ................................ 190Engine Brake .............................. 77, 118Engine Derate ..................................... 81Engine Identification ............................. 5Engine Idling .................................... 104Engine Oil Pressure Gauge ................ 77Engine Oil ......................................... 158Engine Overview ...................... 156, 157Engine Service ................................. 154Engine Shutdown ....................... 80, 104Engine Speed ..................................... 77Engine Storage ................................. 163Engine Warm-Up .............................. 103Engine Warranty Certificate ............... 26Engine .............................................. 108

INDEX

Ethanol and Propylene Charts ......... 176Exterior and Interior Clean ............... 206

F

Federal and Canadian EmissionControl System Warranty ................... 13Federal, Canadian andCalifornia Emission ControlWarranty Statement ........................... 14Filter Element Installation ................. 190Fluid Refill ......................................... 127Fog lights ........................................... 89Forced Neutral ................................... 81Fresh Air Vent ..................................... 93Fuel / Water Separator ..................... 182Fuel Additives ................................... 180Fuel consumption ..................... 107–109Fuel Filter ........................................... 81Fuel Filters ........................................ 181Fuel Storage ..................................... 180Fuel System ..................................... 179Fuel Tank Cap .................................... 99Fuel Tanks ........................................ 100Fuel .................................................. 100

G

Gauges ............................................... 76Grade Gripper .................................... 80Gradients .......................................... 108Grounding Practices ........................ 165GuardDog® Connect ........................... 3

H

Hazard Warning ................................. 90Headlights .......................................... 89Headwinds ....................................... 108High Beam ......................................... 90High beams ........................................ 80High engine speeds ......................... 109High Exhaust Temperature (HEST) ..... 81Hill driving technique ....................... 109Hood Lubrication ............................. 198Hot Check ........................................ 123Hour Meter ......................................... 77

I

Indicator Lamps ................................. 80Inflation Pressure ............................. 184Initial Valve Adjustment Interval ........... 4

J

Jump Starting Engine ...................... 219

K

Key ..................................................... 70Kickdown ......................................... 119

L

License Plate Mounting ................... 209Light Control ...................................... 89Lighting ............................................ 168Load Test ......................................... 168Locking .............................................. 70

Low Beam .......................................... 90Lowering the Cab ......................... 85, 87

M

Malfunction Indicator Lamp ............... 80Metric Conversions .......................... 210Microphone ........................................ 94Moto Mirror System ........................... 95

N

Neutral ................................................ 80Noise, Vibration and Harshness ....... 171

O

Odometer ........................................... 77Oil and Filter Change Intervals ......... 161Oil Capacity and Viscosity ............... 162Oil Change ....................................... 159Oil Filters Change ............................. 160Oil Filters .......................................... 158

P

Parking Brake ..................................... 80Parking Lights .................................... 89Parts and Service Support ................... 2Power Divider ................................... 111Power Steering Fluid ........................ 193Power Take Off ................................... 80Premium Tech Tool™ (PTT) .................. 2Pressure Wash ................................. 206Pre-Trip Inspection ........................... 140Pre-trip ............................................. 141Preventive Maintenance ....................... 4

INDEX

Prohibited Additives ......................... 180

R

Radio ................................................ 132Recirculation Button .......................... 83Releasing the Brakes ....................... 217Retarder Mode ................................. 119Rubber Bushings ............................. 197Rust Protection ................................ 198

S

Safety Labels ....................................... 8Seat Belt Maintenance ..................... 208Seat Belts ........................................... 66Seat .................................................... 91Selective Catalytic Reduction (SCR) .. 80Service and Assistance ........................ 2Shift Schedules ........................ 116, 118Shift Selector .................................... 116SiriusXM® ........................................ 133Spring Bushings ............................... 197Springs ............................................. 197Starting the engine ........................... 109Surge Tank Cap ................................ 175

T

Tachometer ........................................ 77Tell-Tale .............................................. 78Temperature Control Knob ................. 83Temporary Loss of Power Output ........ 4Tilting the Cab .............................. 84, 86Tire Inflation ...................................... 186Tires, Wheels and Hub ..................... 184

Tow Hooks ....................................... 215Towing Backwards ........................... 216Towing Configurations ..................... 216Towing Sideways ............................. 216Towing with Rear Suspension Lifted 214Towing, Lifting General .................... 216Towing, Lifting the FrontSuspension ...................................... 214Towing, Lifting with Leaf Spring ....... 216Towing, Maximum Load DuringLifting ............................................... 215Towing, Rear Suspension ................ 216Towing, Unloading ........................... 215Transmission Fluid ........................... 120Transmission Identification ................... 6Transmission Nameplate .................. 115Transmission ...................................... 81Truck Warranty Certificate .................. 20Turbocharger .................................... 170Turn Signal ......................................... 90

U

Unlocking ........................................... 70

V

Vehicle Cleaning ............................... 206Vehicle Speed .................................. 112

W

Wheel Nut Tighten ........................... 186Wiper Blades .................................... 205

*CID0123456*

*CID0123456*

dear mack® owner - big truck rental

Documents