Mack TerraPro LEU 2010 Service manual

Mack
®
LEU Series
21394654
21394654 21394654
April 2010
© Mack Trucks, Inc. 2010
Printed in U.S.A.
Mack
®
TerraProTM Series
(LEU Series)
Mack
®
TerraProTM Series
(LEU Series)

Foreword
Thismanualcontainsinformationconcerningtheoperationand
functionoftheMackLinkSystem.Theinformationinthismanual
appliestovehiclesbuiltApril2010andlater.Pleasekeepthismanual
inthevehicleatalltimes.
Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)and
MackTrucksInc.,shouldbeinformedimmediatelyifyou
believethatthevehiclehasadefectthatcouldcauseacrash,injury
ordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)
327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation,
Washington,DC20590,byTTYat1(800)424-9153,orvisittheir
websiteatwww.nhtsa.dot.gov.
MackTruck,Inc.
Greensboro,NCUSA
Ordernumber:PV776-21394654
©2010MackTrucks,Inc.,Greensboro,NCUSA
Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionofMackTrucks,Inc.

Contents
INTRODUCTION............................................................................................................1
TOTHEOWNER..........................................................................................................1
InAppreciation..........................................................................................................1
AboutThisHandbook................................................................................................2
THEVEHICLE..............................................................................................................3
BasicConguration...................................................................................................3
VehicleManagementandControlSystem(V-MAC®).............................................3
COMPONENTIDENTIFICATION..............................................................................4
VINLocations............................................................................................................4
EngineIdentication..................................................................................................5
EngineInformationPlate...........................................................................................6
CleanIdleEngines.....................................................................................................7
TransmissionIdentication........................................................................................8
WARRANTYINFORMA TION..................................................................................10
AirBrakeSystem.....................................................................................................10
ENGINEGASEOUSEMISSIONCONTROLSYSTEMS....................................10
EmissionsControlSystemWarranty.......................................................................11
ENGINEGASEOUSEMISSIONSCONTROLSYSTEMW ARRANTY.............13
FEDERALEMISSIONREQUIREMENTS............................................................14
EMISSIONCONTROLSYSTEMSW ARRANTY—CALIFORNIA..................14
EmissionsControlSystemWarranty.......................................................................16
SERVICELITERA TURE............................................................................................20
MACKClass8–ComponentsServiceManual.......................................................20
MACKClass8–CustomCollatedServiceManualonCD....................................20
CUSTOMERSERVICE..............................................................................................21
Call1-800-866-1177forMACKOneCall™...........................................................21
QuestionsandComplaints.......................................................................................21
Addresses.................................................................................................................22
AdditionalAssistance..............................................................................................22
REPORTINGSAFETYDEFECTS.............................................................................24
UnitedStates............................................................................................................24
Canada......................................................................................................................24
Mexico.....................................................................................................................24
EVENTDATARECORDINGDEVICES...................................................................25
SAFETYINFORMATION...........................................................................................26
SAFETYSTA TEMENT..............................................................................................26
CERTIFICATIONLABELS........................................................................................28
SafetyCerticationLabel........................................................................................28
ADVISORYLABELS.................................................................................................30
AdvisoryLabelLocations(OnV ehicle)..................................................................30
CABENTRY/EXIT.....................................................................................................39
Three-LimbContact.................................................................................................39
DriverSide...............................................................................................................41
PassengerSide.........................................................................................................43
SAFETYTIPSFORCOLDWEA THEROPERATION.............................................44
DriverVisibility.......................................................................................................44

CabDoorSealsandKeyLocks...............................................................................45
OutsideMirrorHeater..............................................................................................45
AirHornSnowShield..............................................................................................46
FireExtinguisher(Optional)....................................................................................46
INSTRUMENTSANDCONTROLS...........................................................................47
CABINTERIOR—LEFT..........................................................................................47
CABINTERIOR—RIGHT.......................................................................................48
INSTRUMENTPANEL..............................................................................................49
Tell-Tales..................................................................................................................49
PanelArrangement...................................................................................................50
INSTRUMENTPANELGAUGELAYOUT..............................................................51
PanelsA,B,CandD...............................................................................................52
PanelE.....................................................................................................................53
PanelF.....................................................................................................................54
DPFINHIBITROADSPEEDLIMITING(RSL)...................................................62
CABCLIMATECONTROL.......................................................................................68
LIGHTCONTROLPANEL........................................................................................69
STEERINGCOLUMN................................................................................................70
CombinationStarterandElectricalSwitch..............................................................70
MISCELLANEOUSCONTROLS..............................................................................71
DomeLight..............................................................................................................71
AirHorn...................................................................................................................71
FreshAirVent..........................................................................................................72
AccessoryPowerOutlets.........................................................................................72
PRE-TRIPINSPECTIONANDDAILYMAINTENANCE......................................73
PRE-TRIP....................................................................................................................73
Pre-TripInspectionQuickList................................................................................73
OPERATION..................................................................................................................86
.....................................................................................................................................86
NewVehicleBreak-In..............................................................................................86
WINDSHIELDWASHERRESERVOIR....................................................................88
CABTILTOPERA TION.............................................................................................89
TiltingtheCab.........................................................................................................90
LoweringtheCab.....................................................................................................92
BleedingtheCabTiltSystem..................................................................................93
DOORS........................................................................................................................94
OpeningtheCabDoor.............................................................................................94
LockingtheCabDoor..............................................................................................94
Right-Side(Folding)Door.......................................................................................94
FoldingtheDoor......................................................................................................97
UnfoldingtheDoor................................................................................................100
SEATBEL TS.............................................................................................................102
SeatBeltOperation................................................................................................102
FasteningSeatBelt................................................................................................102
RIGHT-SIDERESTRAINT......................................................................................105

SEATADJUSTMENT...............................................................................................106
Right-SideFoldingSeat.........................................................................................106
AirSeat..................................................................................................................107
MIRRORSYSTEMS.................................................................................................109
MotoMirrorSystem..............................................................................................109
MACKENGINEINFORMATION...........................................................................112
PrecautionsandWarnings......................................................................................112
EngineModelDesignations...................................................................................113
CRUISECONTROLOPERATION..........................................................................114
SpeedControlSwitches.........................................................................................114
DisengagingCruiseControl...................................................................................115
MACKPOWERLEASH™ENGINEBRAKE(IFEQUIPPED)..............................116
EngineBrakeSwitch..............................................................................................117
HowtheEngineBrakeisActivated.......................................................................117
CruiseControlwiththeMACKPowerLeash™EngineBrake.............................118
ONTHEROADWITHTHEMACKPOWERLEASH™ENGINEBRAKE.........119
OverFlatTerrain....................................................................................................119
DescendingaGrade...............................................................................................120
OnSlipperyRoadSurfaces....................................................................................122
BRAKEOPERATION...............................................................................................124
AirBrakeSystem...................................................................................................124
AutomaticSlackAdjusters....................................................................................125
ParkingBrakeSystem............................................................................................125
ParkingBrakeOperation........................................................................................126
Parking...................................................................................................................126
Anti-LockBrakeSystem(ABS)............................................................................127
AutomaticTractionControl(A TC)(IfEquipped).................................................130
WorkBrakeSystem...............................................................................................131
GOODDRIVINGHABITS.......................................................................................133
WeightRatings.......................................................................................................133
Instruments.............................................................................................................133
ShuttingDowntheEngine.....................................................................................133
GeneralObservation..............................................................................................133
STARTINGTHEVEHICLE.....................................................................................134
GeneralInformation...............................................................................................134
PushButtonStarters...............................................................................................134
AirStarters.............................................................................................................135
EngineWarm-Up...................................................................................................138
EngineIdling..........................................................................................................138
ShuttingDowntheEngine.....................................................................................139
COLDWEATHEROPERA TION.............................................................................141
ColdWeatherStartingTips....................................................................................141
EngineBlockHeaters............................................................................................142
MOVINGTHEVEHICLE—GENERALINFORMA TION...................................143
Braking...................................................................................................................143
EngineTemperature...............................................................................................143
TRANSMISSIONSHIFTINGINSTRUCTIONS.....................................................145

StatusLights..........................................................................................................148
TransmissionModuleLocation.............................................................................149
AXLES.......................................................................................................................150
RearAxlesOtherThanMACK.............................................................................150
MACKRearAxles.................................................................................................150
EngagingthePowerDividerLockout....................................................................151
ExtendedIdlingandAftertreatmentSystemConditioning.......................................154
Mack,US10EmissionsSolution.................................................................................155
DIESELPARTICULA TEFILTERS.........................................................................155
ExhaustAftertreatmentSystem.................................................................................158
SafetyInformation.................................................................................................159
ExhaustAftertreatmentSystemComponentsand................................................160
SelectiveCatalyticReduction(SCR)....................................................................160
DieselExhaustFluid(DEF)...................................................................................162
AftertreatmentDieselParticulateFilter(DPF)......................................................165
AftertreatmentControlModule(ACM).................................................................166
ExhaustAftertreatmentSystem............................................................................166
DriverWarningsandOnBoardDiagnostics(OBD).............................................172
OnBoardDiagnostics(OBD)................................................................................172
InstrumentCluster..................................................................................................173
MalfunctionIndicatorLamp(MIL).......................................................................174
AftertreatmentDEFTankLevel-DriverWarning&Inducement........................175
AftertreatmentDEFQuality-DriverWarning&Inducement..............................176
MisllingDieselorAftertreatmentDEFTanks.....................................................177
SCRTampering-DriverWarning&Inducement.................................................178
WarrantyandMaintenance....................................................................................179
ExhaustAftertreatmentSystemMaintenance........................................................179
EngineMaintenanceIntervals................................................................................179
MAINTENANCEANDLUBRICATION..................................................................180
MAINTENANCEINTRODUCTION.......................................................................180
TURBOCHARGER...................................................................................................181
CLEANINGYOURVEHICLE.................................................................................182
ExteriorWashing...................................................................................................182
CabandHood........................................................................................................184
Chassis...................................................................................................................184
CabInterior............................................................................................................184
Waxing...................................................................................................................185
Polishing................................................................................................................185
WinterWarnings....................................................................................................185
TOWING...................................................................................................................186
ENGINEOILLEVELCHECK.................................................................................188
PowerSteeringReservoir......................................................................................189
FUELTANK..............................................................................................................190
FuelTankCap........................................................................................................190
FUELING..................................................................................................................191

BioDiesel................................................................................................................192
B5ApprovalForMACKUS2010CertiedProducts..........................................192
COOLINGSYSTEM.................................................................................................194
CoolantLevelCheck..............................................................................................194
DrainingtheCoolingSystem.................................................................................195
RellingtheCoolingSystem.................................................................................195
ProtectingtheCoolingSystem..............................................................................196
CoolingSystemMaintenance................................................................................197
AccessoryDriveBeltRouting...............................................................................198
HEADLIGHTS..........................................................................................................199
BulbReplacement..................................................................................................199
WHEELS...................................................................................................................199
WheelInspection...................................................................................................199
Tires.......................................................................................................................200
BATTERY..................................................................................................................203
Jump-StartingEngine.............................................................................................203
ELECTRICAL...........................................................................................................205
CircuitBreakerandRelayPanels..........................................................................205
ElectricalGrease....................................................................................................209
CircuitProtectionCharts........................................................................................210
METRICCONVERSIONS.........................................................................................212
METRICCONVERSIONS.......................................................................................212

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

INTRODUCTION1
TOTHEOWNER
InAppreciation
ThankyouforbuyingaMackK®vehicle.Withpropercareandmaintenance,
yournewMack®T erraPro™LEUmodelwillhelpyougainacompetitiveedge
withitsfuel-efcientdrivetraincombinations,lowmaintenance,extended
serviceintervalsand,eventually,goodresalevalue.
TheMack®TerraPro™LEUmodelisavailableforawiderangeof
applications.Becauseofthisversatility,drivetrainsandcomponentsvaryand
operatinginstructionsmaydifferfromonemodeltoanother.Whileevery
efforthasbeenmadetocoverallcurrentarrangements,donothesitateto
consultyourMACKdistributorifaquestionarises.Honest,personalservice
isstandardwitheveryMACKsale.
CAUTION
MackTrucks,Inc.wouldliketopointouttheimportantrolethatthedriverplaysin
thelifeofthevehicle.Onlytrainedandinformeddriversshouldoperatethisvehicle.
We,atMackTrucks,Inc.,hopethatyouwillbehappywithyournewMack®
TerraPro™LEUmodel,andthatyouseemanyyearsoftrouble-freedriving.
Thisvehiclewasbuilttoconformtoallfederalstandardsandregulations
applicableatthetimeofmanufacture.

2INTRODUCTION
AboutThisHandbook
ThishandbookisreferredtoastheMack®TerraPro™LEUSeriesOperator’s
Handbook.ItcoversallMack®TerraPro™LEUmodels.Itsidentication
numberis21394654.Keepthishandbookwiththevehicleatalltimesto
ensurethateachownerand/oroperatorwillhaveaccesstoallpertinent
informationrelatingtotheoperationandhandlingofthisvehicle.
Thishandbookwaspreparedtoprovidethedriverwithallrelevantinformation
concerningthedailyoperationofthisvehicle.Pleasereaditthoroughly;
payparticularattentiontoadvisorylabelsthathavebeenincludedtodraw
attentiontoimportantissuesofoperatorsafetyandoverallperformance.
Informationandillustrationsinthishandbookarebasedonthelatest
productionusageatthetimeofprintingandaresubjecttochangewithout
priornotice.
Note:Basicmaintenanceandlubricationproceduresarefoundinthismanual
beginningwith“MAINTENANCEINTRODUCTION”,page180.Forfurther
information,refertotheMaintenanceandLubricationManual(21394653).Other
importantinformationcanbefoundintheEmissionControlSystemsforMACK
DieselEngineManual(21351488).

INTRODUCTION3
THEVEHICLE
BasicConguration
TheMack®TerraPro™LEUmodelhasalow-entry,cab-forward-style
operatorscompartment.One-stepentryanddualsteering/braking
arrangementsmakeitaverypopularandpracticalvehicleforrefuse
managementcompanies.
VehicleManagementandControlSystem
(V-MAC®)
TheVehicleManagementandControlSystem(V-MAC)isanelectronic
controlsystemthatmanagesengineandvehiclefunctions.Inaddition,the
DataMax™portionofV-MACmonitorsandstoresavarietyofinformation(i.e.,
maintenanceschedules,overspeedlogs,faulttables,tripsummaries).
ForacompletedescriptionoftheV-MACIVsystem,refertotheapplicable
V-MAC®Operator’sGuide,whichissuppliedwiththevehicle.
Additionalinformationconcerningservice,diagnostics,programmingand
vendorequipmentinterfaceapplicationisavailablefromtheMackTrucks,Inc.
ServicePublicationsDepartment.ContactyourlocalMACKdealerfordetails.
WARNING
NevercutintotheV-MACsystemwireharnesstopoweradditionalequipment.If
suchequipmentistobeinstalled,contactyourMACKdealerforassistance.

4INTRODUCTION
COMPONENTIDENTIFICATION
Locatethefollowingserialnumbersandwritethemintheboxesprovided
nexttoeachillustration.
VINLocations
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,afterwhichtheenginewillrevertback
tolowidle.VehiclesequippedwithaCleanIdleengineareidentiedbya
labelwhichisafxedtothelowerportionofthedriver’ssidedooroncab-over
models(LEU).
W2056289
CleanIdleEngineLabel

8INTRODUCTION
TransmissionIdentication
TheAllisonRDSandHStransmissionidenticationplateislocatedonthe
rearrightsideofthemaincase,nearthelowerend.
C0029555
TheMACKcarrierassemblyserialnumberislocatedonthefrontrightside
ofthehousing.
C0028950
TheEaton®Spicer®rearaxleserialnumberislocatedontherearofthe
axlehousingtowardthecarrier.
C0028951

INTRODUCTION9
TheEaton®Spicer®carrierassemblyserialnumberislocatedontheleft
sideoftheforwardcarrier,andthetopoftherearcarrier.
C0028952
TheMERITORrearaxleidenticationtagislocatedontheleftorrightrearof
therearaxlehousing,nexttothecarrier.
C0028953
TheMERITORcarrierassemblyserialnumberislocatedontheleftsideof
theforwardcarrier,andthetopoftherearcarrier.
C0028954