Mack Granite GU Series Service manual

Mack
®
GU Series
21394647
21394647 21394647
April 2010
© Mack Trucks, Inc. 2010
Printed in U.S.A.
Mack
®
Granite
TM
Series
(GU Series)
Mack
®
Granite
TM
Series
(GU Series)

Foreword
Thismanualcontainsinformationconcerningtheoperationand
functionoftheMackLinkSystem.Theinformationinthismanual
appliestovehiclesbuiltApril2010andlater.Pleasekeepthismanual
inthevehicleatalltimes.
Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)and
MackTrucksInc.shouldbeinformedimmediatelyifyoubelievethat
thevehiclehasadefectthatcouldcauseacrash,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)
327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation,
Washington,DC20590,byTTYat1(800)424-9153,orvisittheir
websiteatwww.nhtsa.dot.gov.
MackTrucksInc.
Greensboro,NCUSA
Ordernumber:PV776-21394647
©2010MackTruckInc.,Greensboro,NCUSA
Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionofMackTrucksInc.

Contents
INTRODUCTION............................................................................................................1
TOTHEOWNER..........................................................................................................1
InAppreciation..........................................................................................................1
AboutThisHandbook................................................................................................2
THEVEHICLE..............................................................................................................3
BasicConguration...................................................................................................3
VehicleManagementandControlSystem(V-MAC®).............................................3
COMPONENTIDENTIFICATION..............................................................................4
VINLocations............................................................................................................4
EngineIdentication..................................................................................................5
EngineInformationPlate...........................................................................................6
CleanIdleEngines.....................................................................................................7
TransmissionIdentication........................................................................................7
WARRANTYINFORMATION..................................................................................10
AirBrakeSystem.....................................................................................................11
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................11
EmissionsControlSystemWarranty.......................................................................13
ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............15
FEDERALEMISSIONREQUIREMENTS............................................................16
EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................16
EmissionsControlSystemWarranty.......................................................................18
SERVICELITERATURE............................................................................................22
–MACKClass8–ComponentsServiceManual....................................................22
–Class8–CustomCollatedServiceManual..........................................................22
–Class8–CustomCollatedServiceManualonCD..............................................22
CUSTOMERSERVICE..............................................................................................23
Call1-800-866-1177forMACKOneCall™...........................................................23
QuestionsandComplaints.......................................................................................23
Addresses.................................................................................................................24
AdditionalAssistance..............................................................................................25
REPORTINGSAFETYDEFECTS.............................................................................26
UnitedStates............................................................................................................26
Canada......................................................................................................................26
Mexico.....................................................................................................................26
EVENTDA TARECORDINGDEVICES...................................................................27
SAFETYINFORMATION...........................................................................................28
SAFETYSTATEMENT..............................................................................................28
CERTIFICA TIONLABELS........................................................................................30
SafetyCerticationLabel........................................................................................30
ADVISORYLABELS.................................................................................................32
AdvisoryLabelLocations(OnV ehicle)..................................................................33
TRUCK-TRACTORCONSPICUITY.........................................................................43
CABENTRY/EXIT.....................................................................................................44
Three-LimbContact.................................................................................................44
DriverSide...............................................................................................................46
PassengerSide.........................................................................................................48

DeckPlateAccess....................................................................................................50
SAFETYTIPSFORCOLDWEA THEROPERA TION.............................................52
DriverVisibility.......................................................................................................52
CabDoorSealsandKeyLocks...............................................................................53
OutsideMirrorHeater..............................................................................................53
AirHornSnowShield..............................................................................................54
EmergencyReectorKit..........................................................................................54
FireExtinguisher(Optional)....................................................................................54
INSTRUMENTSANDCONTROLS...........................................................................55
CABINTERIOR..........................................................................................................55
INSTRUMENTPANEL..............................................................................................56
Tell-Tales..................................................................................................................56
PanelArrangement...................................................................................................57
INSTRUMENTPANELGAUGELAYOUT..............................................................58
PanelA.....................................................................................................................60
PanelB.....................................................................................................................61
PanelC.....................................................................................................................63
PanelD.....................................................................................................................64
FunctionofOptionalSwitches.................................................................................80
CABCLIMA TECONTROL.......................................................................................87
SLEEPERCLIMA TECONTROL..............................................................................89
LIGHTCONTROLPANEL........................................................................................90
LOWERCONSOLEPANEL......................................................................................91
STEERINGCOLUMN................................................................................................92
CombinationStarterandElectricalSwitch..............................................................92
SteeringWheelAdjustment.....................................................................................92
TurnSignalLever....................................................................................................93
StalkSwitch(IfEquipped,Co-Pilot®Only)...........................................................94
FLOORPEDALS........................................................................................................95
MISCELLANEOUSCONTROLS..............................................................................96
DomeLight..............................................................................................................96
InteriorCabLights(SleeperCab)............................................................................97
AirHorn...................................................................................................................97
FreshAirV ent..........................................................................................................98
CabAirFilter...........................................................................................................99
Microphone..............................................................................................................99
AccessoryPowerOutlets.......................................................................................100
OPERATION................................................................................................................103
PRE-TRIPINSPECTIONANDDAILYMAINTENANCE.....................................103
Pre-TripInspectionQuickList..............................................................................104
NewV ehicleBreak-In............................................................................................115
WINDSHIELDW ASHERRESERVOIR..................................................................117
HOODOPERA TION.................................................................................................118
OpeningtheHood..................................................................................................118
ClosingtheHood...................................................................................................120

LockingtheHood..................................................................................................121
SnowplowHoodOption........................................................................................122
HOSETENDERS......................................................................................................123
DOORS......................................................................................................................124
StandardDoorPanel..............................................................................................124
PowerDoorPanel(Optional).................................................................................125
OpeningtheCabDoor...........................................................................................126
LockingtheCabDoor............................................................................................126
PowerWindowRegulators....................................................................................126
REMOTEKEYLESSENTRY—(OPTIONAL)......................................................127
TransmitterOperations..........................................................................................128
BatteryReplacement..............................................................................................128
SEATBELTS.............................................................................................................132
SeatBeltOperation................................................................................................132
FasteningSeatBelt................................................................................................132
AdjustableD-RingShoulderBelts(ifequipped)...................................................134
Komfort®LatchSystem........................................................................................135
SEATADJUSTMENTANDRECLINE(IFEQUIPPED)........................................137
MIRRORBREAKAWAYSTRUT............................................................................138
MACKENGINEINFORMA TION...........................................................................139
PrecautionsandWarnings......................................................................................139
EngineModelDesignations...................................................................................140
TIREPRESSURECONTROLSYSTEM(IFEQUIPPED)......................................141
OperatingtheDanaTirePressureControlSystem................................................141
TireChangingProcedure.......................................................................................147
CRUISECONTROLOPERA TION..........................................................................149
SpeedControlSwitches.........................................................................................149
SettingCruiseControl...........................................................................................149
DisengagingCruiseControl...................................................................................150
MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................151
EngineBrakeSwitch..............................................................................................151
HowtheEngineBrakeisActivated.......................................................................152
CruiseControlwiththeMACKPowerLeash™EngineBrake.............................153
ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........154
OverFlatTerrain....................................................................................................154
DescendingaGrade...............................................................................................155
OnSlipperyRoadSurfaces....................................................................................157
BRAKEOPERA TION...............................................................................................159
AirBrakeSystem...................................................................................................159
AutomaticSlackAdjusters....................................................................................160
ParkingBrakeSystem............................................................................................160
ParkingBrakeOperation........................................................................................161
Parking...................................................................................................................161
Anti-LockBrakeSystem(ABS)............................................................................161
AutomaticTractionControl(A TC)(IfEquipped).................................................166
GOODDRIVINGHABITS.......................................................................................168
WeightRatings.......................................................................................................168

Instruments.............................................................................................................168
ShuttingDowntheEngine.....................................................................................168
GeneralObservation..............................................................................................168
STARTINGTHEVEHICLE.....................................................................................169
GeneralInformation...............................................................................................169
PushButtonStarters...............................................................................................169
AirStarters.............................................................................................................170
EngineWarm-Up...................................................................................................173
EngineIdling..........................................................................................................173
ShuttingDowntheEngine.....................................................................................174
COLDWEA THEROPERA TION.............................................................................176
ColdWeatherStartingTips....................................................................................176
EngineBlockHeaters............................................................................................177
Winterfronts...........................................................................................................178
COUPLINGATRAILER..........................................................................................181
UNCOUPLINGATRAILER....................................................................................183
MOVINGTHEVEHICLE—GENERALINFORMA TION...................................185
Braking...................................................................................................................185
Shifting...................................................................................................................185
EngineTemperature...............................................................................................186
Clutch(IfEquipped)..............................................................................................186
POWERTAKE-OFF(PTO)OPERA TION...............................................................191
PTOPrecautions....................................................................................................191
PTOClassication.................................................................................................192
Side-MountedPTOLocations...............................................................................192
PTOOperatingProcedures....................................................................................192
TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................193
ShiftingInstructionsforAllisonAutomaticTransmissions..................................193
MACKT306GShiftingInstructions.....................................................................194
MACKTM308ShiftingInstructions.....................................................................195
MACKTM308MShiftingInstructions.................................................................197
MACKTM309ShiftingInstructions.....................................................................200
MACKTM309MShiftingInstructions.................................................................202
MACKT309,T309LandT309LRShiftingInstructions......................................204
MACKT310ShiftingInstructions........................................................................208
MACKT310M,T310MEandT310MLRShiftingInstructions...........................210
MACKT313-T313L-T313LRShiftingInstructions.............................................214
MACKT31321,T313L21andT313LR21ShiftingInstructions..........................218
MACKT318,T318LandT318LRShiftingInstructions......................................222
MACKT31821,T318L21andT318LR21ShiftingInstructions..........................228
AXLES.......................................................................................................................234
RearAxlesOtherThanMACK.............................................................................234
MACKRearAxles.................................................................................................234
EngagingthePowerDividerLockout....................................................................235
All-Wheel-DriveinGUChassis(IfEquipped).....................................................236
ExtendedIdlingandAftertreatmentSystemConditioning.......................................238

Mack,EPA2010EmissionsSolution...........................................................................239
DIESELPARTICULA TEFILTERS(IFEQUIPPED)..............................................239
ExtendedIdlingandAftertreatmentSystemConditioning...................................242
ExhaustAftertreatmentSystem.................................................................................243
SafetyInformation.................................................................................................244
ExhaustAftertreatmentSystemComponentsand................................................245
SelectiveCatalyticReduction(SCR)....................................................................245
DieselExhaustFluid(DEF)...................................................................................248
AftertreatmentDieselParticulateFilter(DPF)......................................................251
AftertreatmentControlModule(ACM).................................................................252
ExhaustAftertreatmentSystem............................................................................253
DriverWarningsandOnBoardDiagnostics(OBD).............................................258
OnBoardDiagnostics(OBD)................................................................................258
InstrumentCluster..................................................................................................259
MalfunctionIndicatorLamp(MIL).......................................................................260
AftertreatmentDEFTankLevel-DriverWarning&Inducement........................261
AftertreatmentDEFQuality-DriverWarning&Inducement..............................262
MisllingDieselorAftertreatmentDEFTanks.....................................................263
SCRTampering-DriverWarning&Inducement.................................................264
WarrantyandMaintenance....................................................................................265
ExhaustAftertreatmentSystemMaintenance........................................................265
EngineMaintenanceIntervals................................................................................265
MAINTENANCEANDLUBRICATION..................................................................266
MAINTENANCEINTRODUCTION.......................................................................266
TURBOCHARGER...................................................................................................267
CLEANINGYOURVEHICLE.................................................................................268
ExteriorWashing...................................................................................................268
CabandHood........................................................................................................270
Chassis...................................................................................................................270
CabInterior............................................................................................................271
Waxing...................................................................................................................271
Polishing................................................................................................................271
WinterWarnings....................................................................................................271
TOWING...................................................................................................................272
ENGINEOILLEVELCHECK.................................................................................274
ChassisEquippedwithSnowplowHoodOption...................................................275
PowerSteeringReservoir......................................................................................276
FUELTANK..............................................................................................................277
FuelTankCap........................................................................................................277
FUELING..................................................................................................................278
BioDiesel................................................................................................................279
B5ApprovalForMackUS10CertiedProducts..................................................280
COOLINGSYSTEM.................................................................................................281
CoolantLevelCheck..............................................................................................281
DrainingtheCoolingSystem.................................................................................282
RellingtheCoolingSystem.................................................................................282

ProtectingtheCoolingSystem..............................................................................282
CoolingSystemMaintenance................................................................................284
AccessoryDriveBeltRouting...............................................................................284
HEADLIGHTS..........................................................................................................286
BulbReplacement..................................................................................................286
WHEELS...................................................................................................................287
WheelInspection...................................................................................................287
Tires.......................................................................................................................288
BATTERY..................................................................................................................291
Jump-StartingEngine.............................................................................................291
ELECTRICAL...........................................................................................................293
CircuitBreakerandRelayPanels..........................................................................293
ElectricalGrease....................................................................................................296
CircuitProtectionCharts........................................................................................296
ElectricalAccessoryConnectionPoints................................................................299
METRICCONVERSIONS.........................................................................................304
METRICCONVERSIONS.......................................................................................304

SafetyInformation
IMPORTANT:Beforedrivingthis
vehicle,becertainthatyouhaveread
andthatyoufullyunderstandeachand
everystepofthedrivingandhandling
informationinthismanual.Becertain
thatyoufullyunderstandandfollowall
safetywarnings.
ITISIMPORTANTTHATTHE
FOLLOWINGINFORMA TIONBE
READ,UNDERSTOODANDALW AYS
FOLLOWED.
Thefollowingtypesofadvisoriesareused
throughoutthismanual:
DANGER
Dangerindicatesanunsafepracticethat
couldresultinseriouspersonalinjury
ordeath.Adangeradvisorybanneris
inwhitetypeonablackbackground
withablackborder.
WARNING
Warningindicatesanunsafepractice
thatcouldresultinpersonalinjury.A
warningadvisorybannerisinblack
typeonagraybackgroundwithablack
border.
CAUTION
Cautionindicatesanunsafepracticethat
couldresultindamagetotheproduct.
Acautionadvisoryisinblacktypeona
whitebackgroundwithablackborder.
Note:Noteindicatesaprocedure,practice,
orconditionthatmustbefollowedinorder
forthevehicleorcomponenttofunction
inthemannerintended.

INTRODUCTION1
TOTHEOWNER
InAppreciation
ThankyouforbuyingaMACK®vehicle.Withpropercareandmaintenance,
yournewMack®Granite™GUmodelwillhelpyougainacompetitiveedge
withitsfuel-efcientdrivetraincombinations,lowmaintenance,extended
serviceintervalsand,eventually,goodresalevalue.
TheMack®Granite™GUmodelisavailableforawiderangeofapplications.
Becauseofthisversatility,drivetrainsandcomponentsvaryandoperating
instructionsmaydifferfromonemodeltoanother.Whileeveryefforthas
beenmadetocoverallcurrentarrangements,donothesitatetoconsultyour
MACKdistributorifaquestionarises.Honest,personalserviceisstandard
witheveryMACKsale.
CAUTION
MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin
thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.
We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack®
Granite™GUmodel,andthatyouseemanyyearsoftrouble-freedriving.
Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations
applicableatthetimeofmanufacture.

2INTRODUCTION
AboutThisHandbook
ThishandbookisreferredtoastheMack®Granite™GUSeriesOperator’s
Handbook.ItcoversallMack®Granite™GUmodels.Itsidenticationnumber
is.Keepthishandbookwiththevehicleatalltimestoensurethateachowner
and/oroperatorwillhaveaccesstoallpertinentinformationrelatingtothe
operationandhandlingofthisvehicle.
Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation
concerningthedailyoperationofthisvehicle.Pleasereaditthoroughly;
payparticularattentiontoadvisorylabelsthathavebeenincludedtodraw
attentiontoimportantissuesofoperatorsafetyandoverallperformance.
Informationandillustrationsinthishandbookarebasedonthelatest
productionusageatthetimeofprintingandaresubjecttochangewithout
priornotice.
Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual
beginningwith“MAINTENANCEINTRODUCTION”,page266.Forfurther
information,refertotheMaintenanceandLubricationManual.Otherimportant
informationcanbefoundintheEmissionControlSystemsforMACKDieselEngine
Manual.

INTRODUCTION3
THEVEHICLE
BasicConguration
TheMack®Granite™GUmodelfeaturesaconventionallystyled,aerodynamiccab.
VehicleManagementandControlSystem
(V-MAC®)
TheVehicleManagementandControlSystem(V-MAC)isanelectronic
controlsystemthatmanagesengineandvehiclefunctions.Inaddition,the
DataMax™portionofV-MACmonitorsandstoresavarietyofinformation(i.e.,
maintenanceschedules,overspeedlogs,faulttables,tripsummaries).
ForacompletedescriptionoftheV-MACIVsystem,refertotheapplicable
V-MAC®Operator’sGuide,whichissuppliedwiththevehicle.
Additionalinformationconcerningservice,diagnostics,programmingand
vendorequipmentinterfaceapplicationisavailablefromtheMackTrucks,Inc.
ServicePublicationsDepartment.ContactyourlocalMACKdealerfordetails.
WARNING
NevercutintotheV-MACsystemwireharnesstopoweradditionalequipment.If
suchequipmentistobeinstalled,contactyourMACKdealerforassistance.

4INTRODUCTION
COMPONENTIDENTIFICATION
Locatethefollowingserialnumbersandwritethemintheboxesprovided
nexttoeachillustration.
VINLocations
TheVehicleIdenticationNumber(VIN)isdisplayedintwolocations(aframe
railstampingandalabel).The17-digitVINmustbeidenticalinbothlocations.
TheVINframestampingislocatedontherightoutsideframerailandthe
leftinsideframerail.
C0029554
TheVINlabelislocatedontheinsidedoorframebelowthedriverseat.
C0028941

INTRODUCTION5
EngineIdentication
OntheMACKMPengines,theengineserialnumberisstampedontheleft
sideoftheengineblock,belowtheinletmanifold.
C0028943

6INTRODUCTION
EngineInformationPlate
IncompliancewithFederalandCaliforniaemissionrequirements,an
engineinformationlabelisafxedtoallMACKdieselengines.Thislabel,
whichislocatedonthecylinderheadcoveratthefrontoftheengine,gives
basicengineidenticationinformation(enginemodel,serialnumber,etc.),
advertisedhorsepoweratratedspeed,emissionsregulationstowhichthe
engineconformsandinletandexhaustvalvelashsettings.Examplesofthe
49stateEPAapproved,and50stateEPAandCaliforniaapprovedengine
identicationlabelsaregivenbelow.
W2040455
EngineIdenticationLabel-49StateEPAApprovedEngine
withoutCalifornia"CleanIdle"
W2040456
EngineIdenticationLabel-50StateEPAApprovedEngine
withCalifornia"CleanIdle"

INTRODUCTION7
CleanIdleEngines
TheCaliforniaAirResourcesBoard(ARB)requiresthat2008andlatermodel
yearvehiclesbeequippedwithengineshavingtamper-resistantsoftware
whichlimitsthetimeatwhichtheenginecanidleatspeedsabovelowidle
(550–700rpm).Atspeedsabovelowidle,andwithoutaPTOengaged,idle
timewillbelimitedtoveminutes,afterwhichtheenginewillrevertbacktolow
idle.VehiclesequippedwithaCleanIdleengineareidentiedbyalabelwhich
isafxedtotheleftfrontcornerofthehoodonconventionalmodels(GU).
W2056289
CleanIdleEngineLabel
TransmissionIdentication
TheMACKT300Seriestransmissionserialnumberislocatedontherear
leftsideofthemaincase.

8INTRODUCTION
C0028947
TheAllisonRDS,EVSandSPtransmissionidenticationplateislocatedon
therearrightsideofthemaincase,nearthelowerend.
C0029891
AllEaton®Fuller®transmissionidenticationplatesarelocatedonthe
frontleftsideofthemaincase.
C0028949
TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside
ofthehousing.

INTRODUCTION9
C0028950
TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe
axlehousingtowardthecarrier.
C0028951
TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft
sideoftheforwardcarrier,andthetopoftherearcarrier.
C0028952
TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof
therearaxlehousing,nexttothecarrier.