2007 Maintenance and Lubrication Manual

JAN
PR MAY JUN JUL AUG SEP OCT NOV DEC

JAN FEB MAR APR MAY JUN JUL AUG SEP
AINTENANCE
FEB
TS49407
TS49407
JULY
JULY
2007
2007
FOR MACK® DIESEL POWERED TRUCKS (SUPERSEDES
(SUPERSEDES
LUBRICATION
JUNE
JUNE2007)
2007)
MAR
LUBRICATION
MAINTENAN
AND
APR
UBRICATION
AINTENAN
® MAY FOR MACK
JUN JUL AUGDIESEL POWERED TRUC
SEP OCT
AND
M OCT NOV
MM AINTENANCE
AINTENANCE
NOV DEC
AND
AND
LLUBRICATION
UBRICATION
DEC
OCT NOV DEC FOR

FOR
MACK ® DIESEL
MACK ® DIESEL
POWERED
POWERED
TRUCKS
TRUCKS
TS49407 TS49407
MAINTENANCE MAINTENANCE
AND AND
LUBRICATION FOR LUBRICATION FOR
 
MACK DIESEL MACK DIESEL
POWERED TRUCKS POWERED TRUCKS
The information supplied in this manual is not all-inclusive, and cannot The information supplied in this manual is not all-inclusive, and cannot
take into account all unique situations. take into account all unique situations.
The engine oil/filter and gear oil change intervals outlined in this The engine oil/filter and gear oil change intervals outlined in this
manual pertain to components manufactured by Mack Trucks, Inc. For manual pertain to components manufactured by Mack Trucks, Inc. For
information concerning engine oil/filter and gear oil change intervals for information concerning engine oil/filter and gear oil change intervals for
vendor components, refer to the specific vendor component service vendor components, refer to the specific vendor component service
literature. literature.
The information, specifications and illustrations in this publication are The information, specifications and illustrations in this publication are
based on information that was current at the time of publication, and based on information that was current at the time of publication, and
are subject to change without prior notification. are subject to change without prior notification.
No part of this publication may be reproduced, photocopied or No part of this publication may be reproduced, photocopied or
recorded, stored in a retrieval system, or be transmitted in any form, or recorded, stored in a retrieval system, or be transmitted in any form, or
by any means, either mechanical, electronic, or otherwise without the by any means, either mechanical, electronic, or otherwise without the
prior written consent of Mack Trucks, Inc. prior written consent of Mack Trucks, Inc.
(Revised July 2007, (Revised July 2007,

Supersedes June 2007) © MACK TRUCKS, INC. 2007 Supersedes June 2007) © MACK TRUCKS, INC. 2007
i i
1 1
Figure 1 — Mack Model Chassis Figure 1 — Mack Model Chassis
ii ii
INTRODUCTION INTRODUCTION
INTRODUCTION INTRODUCTION
Preventive maintenance is vital to the life of your new MACK truck. Preventive maintenance is vital to the life of your new MACK truck.
This manual explains the proper preventive maintenance and This manual explains the proper preventive maintenance and
lubrication procedures which should be used on all MACK Class 8 lubrication procedures which should be used on all MACK Class 8
chassis. chassis.
The MACK Preventive Maintenance and Lubrication program outlined The MACK Preventive Maintenance and Lubrication program outlined
in this manual is designed to ensure a long and productive life from in this manual is designed to ensure a long and productive life from
your truck. The program is divided into four maintenance schedules, your truck. The program is divided into four maintenance schedules,
each addressing items which require periodic inspections to ensure each addressing items which require periodic inspections to ensure
efficient, reliable and trouble-free operation. To allow flexibility in efficient, reliable and trouble-free operation. To allow flexibility in
developing a maintenance routine suitable to your operating developing a maintenance routine suitable to your operating
requirements, maintenance intervals in this manual are arranged in requirements, maintenance intervals in this manual are arranged in
miles/kilometers, hours or days of operation. Maintenance instructions, miles/kilometers, hours or days of operation. Maintenance instructions,
specifications and capacities are outlined for quick and easy reference. specifications and capacities are outlined for quick and easy reference.
The service manager at your MACK distributor will be happy to assist The service manager at your MACK distributor will be happy to assist
in customizing a maintenance program tailored to your operating in customizing a maintenance program tailored to your operating
requirements. requirements.
Following the MACK Preventive Maintenance Program is highly Following the MACK Preventive Maintenance Program is highly
recommended to all operators of MACK vehicles because it is the key recommended to all operators of MACK vehicles because it is the key
to lower operating costs both in time and money. The bottom line to a to lower operating costs both in time and money. The bottom line to a
well-run maintenance program is less downtime and increased well-run maintenance program is less downtime and increased
profitability. profitability.
iii iii
SAFETY INFORMATION SAFETY INFORMATION
SAFETY INFORMATION SAFETY INFORMATION

MACK cannot anticipate every possible occurrence which may involve MACK cannot anticipate every possible occurrence which may involve
a potential hazard. An accident can be avoided by recognizing a potential hazard. An accident can be avoided by recognizing
potentially hazardous situations before an accident occurs. Correctly potentially hazardous situations before an accident occurs. Correctly
performed service procedures are critical to technician safety and the performed service procedures are critical to technician safety and the
consequent safe, reliable operation of the vehicle. consequent safe, reliable operation of the vehicle.
Do not perform any service procedures or lubrications until this manual Do not perform any service procedures or lubrications until this manual
has been read and understood. has been read and understood.
Some service procedures may require the use of special tools Some service procedures may require the use of special tools
designed for a specific purpose. These tools must be used in the designed for a specific purpose. These tools must be used in the
manner described in the instructions. Anyone using a procedure or tool manner described in the instructions. Anyone using a procedure or tool
not recommended in this manual must realize he is jeopardizing his not recommended in this manual must realize he is jeopardizing his
safety and the safe operation of the vehicle. Individuals deviating from safety and the safe operation of the vehicle. Individuals deviating from
the instructions set forth in this manual assume all risks of personal the instructions set forth in this manual assume all risks of personal
injury or damage to equipment. injury or damage to equipment.
MAKE SAFETY FIRST . . . MAKE SAFETY FIRST . . .
. . . AND MAKE IT LAST . . . AND MAKE IT LAST
iv iv
ADVISORY LABELS ADVISORY LABELS

Cautionary signal words (Danger-Warning-Caution) may appear in Cautionary signal words (Danger-Warning-Caution) may appear in
various locations throughout this manual. Information accented by one various locations throughout this manual. Information accented by one
of these signal words must be observed to minimize the risk of of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper personal injury to service personnel, or the possibility of improper
service methods which may damage the vehicle or cause it to be service methods which may damage the vehicle or cause it to be
unsafe. Additional Notes and Service Hints are used to emphasize unsafe. Additional Notes and Service Hints are used to emphasize
areas of procedural importance and provide suggestions for ease of areas of procedural importance and provide suggestions for ease of
repair. The following definitions indicate the use of these advisory repair. The following definitions indicate the use of these advisory
labels as they appear throughout the manual: labels as they appear throughout the manual:
Danger indicates an unsafe practice that could result in death or Danger indicates an unsafe practice that could result in death or
serious personal injury. Serious personal injury is considered to serious personal injury. Serious personal injury is considered to
be permanent injury from which full recovery is NOT expected, be permanent injury from which full recovery is NOT expected,
resulting in a change in life style. resulting in a change in life style.
Warning indicates an unsafe practice that could result in personal Warning indicates an unsafe practice that could result in personal
injury. Personal injury means that the injury is of a temporary injury. Personal injury means that the injury is of a temporary
nature and that full recovery is expected. nature and that full recovery is expected.
Caution indicates an unsafe practice that could result in damage to the Caution indicates an unsafe practice that could result in damage to the
product. product.
Note indicates a procedure, practice, or condition that must be followed Note indicates a procedure, practice, or condition that must be followed
in order for the vehicle or component to function in the manner in order for the vehicle or component to function in the manner
intended. intended.
A helpful suggestion that will make it quicker and/or easier to perform a A helpful suggestion that will make it quicker and/or easier to perform a
procedure, while possibly reducing service cost. procedure, while possibly reducing service cost.
v v
2 2
Figure 2 — ASE Certification Figure 2 — ASE Certification
vi vi
MANUAL CONTENTS MANUAL CONTENTS
MAINTENANCE AND LUBRICATION MAINTENANCE AND LUBRICATION
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . i MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . i

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . iv SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . iv
ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . .v ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . .v
DIESEL PARTICULATE FILTERS . . . . . . . . . . . . . . 4 DIESEL PARTICULATE FILTERS . . . . . . . . . . . . . . 4
VEHICLE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . 7 VEHICLE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . 7
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 10 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 10
PREVENTIVE MAINTENANCE PROGRAM . . . . . . 14 PREVENTIVE MAINTENANCE PROGRAM . . . . . . 14
NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . 28 NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . 28
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHASSIS INSPECTION . . . . . . . . . . . . . . . . . . . . . 36 CHASSIS INSPECTION . . . . . . . . . . . . . . . . . . . . . 36
SPECIFIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 69 SPECIFIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 69
FASTENER SIZES, TYPES AND GRADES . . . . . . 71 FASTENER SIZES, TYPES AND GRADES . . . . . . 71
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 91 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 91
COLD WEATHER OPERATION . . . . . . . . . . . . . . 105 COLD WEATHER OPERATION . . . . . . . . . . . . . . 105
HOSE CLAMP TORQUES . . . . . . . . . . . . . . . . . . 110 HOSE CLAMP TORQUES . . . . . . . . . . . . . . . . . . 110
AIR CONDITIONER MAINTENANCE . . . . . . . . . . 111 AIR CONDITIONER MAINTENANCE . . . . . . . . . . 111
AIR CLEANER MAINTENANCE . . . . . . . . . . . . . . 113 AIR CLEANER MAINTENANCE . . . . . . . . . . . . . . 113
TURBOCHARGERS . . . . . . . . . . . . . . . . . . . . . . . 117 TURBOCHARGERS . . . . . . . . . . . . . . . . . . . . . . . 117
DIESEL PARTICULATE FILTER (DPF) . . . . . . . . 119 DIESEL PARTICULATE FILTER (DPF) . . . . . . . . 119
CMCAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 CMCAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . 133 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . 133
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
STEERING KNUCKLE INSPECTION . . . . . . . . . . 179 STEERING KNUCKLE INSPECTION . . . . . . . . . . 179
CARRIER CAPSCREW TORQUE . . . . . . . . . . . . 180 CARRIER CAPSCREW TORQUE . . . . . . . . . . . . 180
FRONT AXLE STATIC SHAKE TEST . . . . . . . . . . 182 FRONT AXLE STATIC SHAKE TEST . . . . . . . . . . 182
SPRING CLIP (U-BOLT) TORQUE . . . . . . . . . . . . 183 SPRING CLIP (U-BOLT) TORQUE . . . . . . . . . . . . 183
MACK AIR SUSPENSIONS . . . . . . . . . . . . . . . . . 187 MACK AIR SUSPENSIONS . . . . . . . . . . . . . . . . . 187
AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . 208 AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . 208
AUXILIARY AXLES . . . . . . . . . . . . . . . . . . . . . . . . 213 AUXILIARY AXLES . . . . . . . . . . . . . . . . . . . . . . . . 213
WHEEL TORQUE PROCEDURES . . . . . . . . . . . . 215 WHEEL TORQUE PROCEDURES . . . . . . . . . . . . 215
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . 224 TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . 224
1 1
MANUAL CONTENTS MANUAL CONTENTS
TIRE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 228 TIRE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 228

DRIVELINE RETARDER . . . . . . . . . . . . . . . . . . . . 230 DRIVELINE RETARDER . . . . . . . . . . . . . . . . . . . . 230
AIR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 232 AIR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 232
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 235 BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 235
CAB MOUNT MAINTENANCE — LEU AND MRU CAB MOUNT MAINTENANCE — LEU AND MRU
MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 247 CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 247
VALVE AND UNIT INJECTOR VALVE AND UNIT INJECTOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
BRAKE DIAGNOSTIC CHART . . . . . . . . . . . . . . . . 259 BRAKE DIAGNOSTIC CHART . . . . . . . . . . . . . . . . 259
SPECIFICATIONS AND CAPACITIES . . . . . . . . . . . . 265 SPECIFICATIONS AND CAPACITIES . . . . . . . . . . . . 265
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . 267 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . 267
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
ANTIFREEZE SPECIFICATIONS . . . . . . . . . . . . . . 284 ANTIFREEZE SPECIFICATIONS . . . . . . . . . . . . . . 284
COOLANT CAPACITIES . . . . . . . . . . . . . . . . . . . . 286 COOLANT CAPACITIES . . . . . . . . . . . . . . . . . . . . 286
LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . 288 LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . 288
MACK ENGINE LINE-UP . . . . . . . . . . . . . . . . . . . . 300 MACK ENGINE LINE-UP . . . . . . . . . . . . . . . . . . . . 300
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . 304 CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . 304
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . 311 MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . 311
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . 312 SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . 312
2 2
MAINTENANCE AND LUBRICATION MAINTENANCE AND LUBRICATION
TABLE OF CONTENTS TABLE OF CONTENTS
DIESEL PARTICULATE FILTERS . . . . . . . . . . . . . . . . . 4 DIESEL PARTICULATE FILTERS . . . . . . . . . . . . . . . . . 4

VEHICLE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 VEHICLE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PREVENTIVE MAINTENANCE PROGRAM . . . . . . . . . 14 PREVENTIVE MAINTENANCE PROGRAM . . . . . . . . . 14
NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . 28 NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . 28
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHASSIS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 36 CHASSIS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 36
3 3
DIESEL PARTICULATE FILTERS DIESEL PARTICULATE FILTERS

Your new MACK chassis is equipped with a 2007 emission compliant Your new MACK chassis is equipped with a 2007 emission compliant
engine and an exhaust aftertreatment system known as a Diesel engine and an exhaust aftertreatment system known as a Diesel
Particulate Filter (DPF), which reduces soot and particulate emissions Particulate Filter (DPF), which reduces soot and particulate emissions
into the atmosphere. Vehicles equipped with a Diesel Particulate Filter into the atmosphere. Vehicles equipped with a Diesel Particulate Filter
require the use of EO-O Premium Plus (or VDS-4) specification high require the use of EO-O Premium Plus (or VDS-4) specification high
performance diesel engine oil and Ultra Low Sulfur Diesel (ULSD) fuel. performance diesel engine oil and Ultra Low Sulfur Diesel (ULSD) fuel.
Use of diesel fuel other than ULSD and engine oils Use of diesel fuel other than ULSD and engine oils
other than EO-O Premium Plus (or VDS-4), will other than EO-O Premium Plus (or VDS-4), will
adversely affect performance, efficiency and durability adversely affect performance, efficiency and durability
of the DPF system and the engine, to the point where of the DPF system and the engine, to the point where
the engine may not run at all. Manufacturer’s the engine may not run at all. Manufacturer’s
warranties will also be rendered void due to usage of warranties will also be rendered void due to usage of
improper fuel. Unapproved fuel additives (including improper fuel. Unapproved fuel additives (including
engine oil) are NOT permitted. engine oil) are NOT permitted.
Mack Trucks, Inc. offers two different types of DPF systems: Mack Trucks, Inc. offers two different types of DPF systems:
앫 Catalyzed DPF (passive/active regeneration) 앫 Catalyzed DPF (passive/active regeneration)
앫 Non-catalyzed DPF (active regeneration) 앫 Non-catalyzed DPF (active regeneration)
as well as two different mounting styles: as well as two different mounting styles:
앫 MACK Vertical Back-of-Cab DPF (both catalyzed and 앫 MACK Vertical Back-of-Cab DPF (both catalyzed and
non-catalyzed) non-catalyzed)
앫 MACK-Cap DPF, which is a space saving unit that is mounted 앫 MACK-Cap DPF, which is a space saving unit that is mounted
inside the frame (catalyzed only) inside the frame (catalyzed only)
The Diesel Particulate Filter takes the place of the standard muffler. The Diesel Particulate Filter takes the place of the standard muffler.
Soot and other particulate matter is collected by a filter inside the unit Soot and other particulate matter is collected by a filter inside the unit
where it is eventually oxidized using a regeneration process that is where it is eventually oxidized using a regeneration process that is
either Passive/Active (catalyzed DPF) or Active (non-catalyzed DPF). either Passive/Active (catalyzed DPF) or Active (non-catalyzed DPF).
With the passive/active regeneration process, soot is collected in the With the passive/active regeneration process, soot is collected in the
filter and oxidized as the vehicle is in operation. An oxidation catalyst filter and oxidized as the vehicle is in operation. An oxidation catalyst
raises the exhaust temperature to approximately 260°C (500°F), the raises the exhaust temperature to approximately 260°C (500°F), the
temperature at which the chemical reaction takes place to oxidize the temperature at which the chemical reaction takes place to oxidize the
soot. When soot loading in the filter reaches a point where it can no soot. When soot loading in the filter reaches a point where it can no
longer be oxidized passively, fuel is injected into the system to raise the longer be oxidized passively, fuel is injected into the system to raise the
temperature inside the filter to approximately 625°C (1157°F), the temperature inside the filter to approximately 625°C (1157°F), the
temperature at which active regeneration takes place. temperature at which active regeneration takes place.
4 4
DPF systems using the active-only (non-catalyzed) process do not DPF systems using the active-only (non-catalyzed) process do not
have an oxidation catalyst. Regeneration takes place after a certain have an oxidation catalyst. Regeneration takes place after a certain
number of engine operating hours, and begins when an air/fuel mixture number of engine operating hours, and begins when an air/fuel mixture
is injected into the thermal regenerator and raises the temperature is injected into the thermal regenerator and raises the temperature
inside the unit to the point where the soot oxidation takes place. inside the unit to the point where the soot oxidation takes place.
The type of DPF system (passive/active or active-only) is based on The type of DPF system (passive/active or active-only) is based on
vehicle application. In general, DPF systems using passive/active vehicle application. In general, DPF systems using passive/active
(catalyzed) regeneration are used in highway and certain vocational (catalyzed) regeneration are used in highway and certain vocational
applications. Active-only (non-catalyzed) DPF systems are for vehicles applications. Active-only (non-catalyzed) DPF systems are for vehicles
used mainly in refuse collection applications. used mainly in refuse collection applications.
When active regeneration occurs (with either system), When active regeneration occurs (with either system),
the temperature of the exhaust will be elevated. DO the temperature of the exhaust will be elevated. DO
NOT park the vehicle with the exhaust outlet under low NOT park the vehicle with the exhaust outlet under low
hanging overhead flammable objects such as trees, hanging overhead flammable objects such as trees,
awnings, etc., that could be damaged by elevated awnings, etc., that could be damaged by elevated
exhaust temperatures. exhaust temperatures.
When active regeneration occurs, an indicator lamp on the instrument When active regeneration occurs, an indicator lamp on the instrument
panel will illuminate to alert the operator. A DPF switch allows the panel will illuminate to alert the operator. A DPF switch allows the
vehicle to either stop or start active regeneration. (Certain conditions vehicle to either stop or start active regeneration. (Certain conditions
must be met, however, before an active regeneration can be manually must be met, however, before an active regeneration can be manually
started.) Refer to the applicable vehicle operator’s manual for a started.) Refer to the applicable vehicle operator’s manual for a
complete description of DPF indicator lamp and switch functions. complete description of DPF indicator lamp and switch functions.
If the vehicle is in a location that may be hazardous If the vehicle is in a location that may be hazardous
when an active regeneration begins (i.e., in close when an active regeneration begins (i.e., in close
proximity to flammable materials or gases), the proximity to flammable materials or gases), the
regeneration should be stopped by pushing the DPF regeneration should be stopped by pushing the DPF
switch to the “Stop Regeneration” position. switch to the “Stop Regeneration” position.
If an active regeneration is stopped by the vehicle If an active regeneration is stopped by the vehicle
operator, it should be initiated at a later time when the operator, it should be initiated at a later time when the
vehicle is in a safe location. However, if an active vehicle is in a safe location. However, if an active
regeneration is stopped too many times, the vehicle regeneration is stopped too many times, the vehicle
must be taken to a MACK service facility. The service must be taken to a MACK service facility. The service
facility will use a service tool to manually initiate the facility will use a service tool to manually initiate the
regeneration. regeneration.
5 5
Diesel Particulate Filter Maintenance Diesel Particulate Filter Maintenance

Maintenance requirements for the DPF systems are as follows: Maintenance requirements for the DPF systems are as follows:
앫 For the non-catalyzed DPF, the ignition electrodes and injection 앫 For the non-catalyzed DPF, the ignition electrodes and injection
nozzle cleaning interval is 161 000 km/100,000 miles or nozzle cleaning interval is 161 000 km/100,000 miles or
2,400 hours, whichever occurs first. 2,400 hours, whichever occurs first.
앫 For the catalyzed DPF, the Aftertreatment Hydrocarbon Injector 앫 For the catalyzed DPF, the Aftertreatment Hydrocarbon Injector
(AHI) must be cleaned at each 240 000 km/150,000 mile or (AHI) must be cleaned at each 240 000 km/150,000 mile or
4,500 hour interval, whichever occurs first. 4,500 hour interval, whichever occurs first.
앫 For both catalyzed and non-catalyzed systems, the ash cleaning 앫 For both catalyzed and non-catalyzed systems, the ash cleaning
interval is 400 000 km/250,000 miles or 4,500 hours, whichever interval is 400 000 km/250,000 miles or 4,500 hours, whichever
occurs first. occurs first.
Diesel Particulate Filter Precautions Diesel Particulate Filter Precautions

Diesel particulate filters and related components cannot be moved or Diesel particulate filters and related components cannot be moved or
altered from the OEM installation in any fashion. altered from the OEM installation in any fashion.
앫 Moving or altering the DPF or related components will result in 앫 Moving or altering the DPF or related components will result in
emission system malfunction or failure. emission system malfunction or failure.
앫 Altering the emissions system is prohibited by the Environmental 앫 Altering the emissions system is prohibited by the Environmental
Protection Agency (EPA). Protection Agency (EPA).
앫 Dealers and/or upfitters (body builders/installers) are not 앫 Dealers and/or upfitters (body builders/installers) are not
authorized to alter or modify the emissions system or any of the authorized to alter or modify the emissions system or any of the
emissions-related components. emissions-related components.
For heated dump bodies, exhaust flow cannot be diverted from the For heated dump bodies, exhaust flow cannot be diverted from the
exhaust system ahead of the DPF system. For vehicles that will be exhaust system ahead of the DPF system. For vehicles that will be
used with a heated dump body, exhaust flow must come from the DPF used with a heated dump body, exhaust flow must come from the DPF
outlet, and exhaust back pressure specifications (18 kPa [2.6 psi] for outlet, and exhaust back pressure specifications (18 kPa [2.6 psi] for
MACK MP7 engines and 21 kPa [3.1 psi] for MACK MP8 engines) MACK MP7 engines and 21 kPa [3.1 psi] for MACK MP8 engines)
cannot be exceeded. The ONLY diesel particulate filter that is approved cannot be exceeded. The ONLY diesel particulate filter that is approved
for heated dump body applications is the MACK-Cap DPF system. The for heated dump body applications is the MACK-Cap DPF system. The
MACK-Cap DPF is a space saver unit that is mounted inside the frame, MACK-Cap DPF is a space saver unit that is mounted inside the frame,
as opposed to the vertical back-of-cab DPF unit. The vertical as opposed to the vertical back-of-cab DPF unit. The vertical
back-of-cab DPF unit is NOT approved for use with heated dump body back-of-cab DPF unit is NOT approved for use with heated dump body
applications. applications.
6 6
VEHICLE BREAK-IN VEHICLE BREAK-IN

To get the most from your new MACK truck, and to ensure many years To get the most from your new MACK truck, and to ensure many years
of reliable, trouble-free operation, the following “break-in” procedures of reliable, trouble-free operation, the following “break-in” procedures
are recommended. are recommended.
During first 5000 km (3000 miles) During first 5000 km (3000 miles)
✓ After the first 200 km (125 miles), retorque the wheel nuts using an ✓ After the first 200 km (125 miles), retorque the wheel nuts using an
accurately calibrated torque wrench. Recheck this torque again accurately calibrated torque wrench. Recheck this torque again
after 800 km (500 miles). after 800 km (500 miles).
✓ Check engine oil and coolant level frequently. ✓ Check engine oil and coolant level frequently.
✓ Check brake and clutch adjustment per recommended schedules ✓ Check brake and clutch adjustment per recommended schedules
and adjust as needed. and adjust as needed.
✓ Observe instruments often and shut down as soon as possible at ✓ Observe instruments often and shut down as soon as possible at
first sign of any abnormal readings. first sign of any abnormal readings.
✓ Check for leaks, loose fasteners, unusual noises, etc., and correct ✓ Check for leaks, loose fasteners, unusual noises, etc., and correct
as necessary. as necessary.
✓ Check spring clip torque (U-bolts). (Reyco suspensions: also check ✓ Check spring clip torque (U-bolts). (Reyco suspensions: also check
equalizer nut torque.) equalizer nut torque.)
✓ At the end of the first 1610 km (1000 miles) of service, check the ✓ At the end of the first 1610 km (1000 miles) of service, check the
U-bolt torque on all MACK air suspensions (including MAXAIR™ U-bolt torque on all MACK air suspensions (including MAXAIR™
40/40A and MAXLITE™ 20–40). 40/40A and MAXLITE™ 20–40).
At the end of first 5000 km (3000 miles) or before 6500 km At the end of first 5000 km (3000 miles) or before 6500 km
(4000 miles) or 3 to 4 months (whichever comes first) (4000 miles) or 3 to 4 months (whichever comes first)
✓ Retorque spring clips (U-bolts). (Reyco suspensions: Retorque ✓ Retorque spring clips (U-bolts). (Reyco suspensions: Retorque
spring clips and equalizer nuts.) spring clips and equalizer nuts.)
✓ Auxiliary axles ✓ Auxiliary axles
앫 Check wheel bearing lubricant and add GO-J oil as 앫 Check wheel bearing lubricant and add GO-J oil as
required. required.
앫 Lubricate king pins (steerable axles). 앫 Lubricate king pins (steerable axles).
앫 Lubricate tie rod ends. 앫 Lubricate tie rod ends.
7 7
At the first A inspection interval At the first A inspection interval

✓ Check front and rear axle alignment and adjust if out of ✓ Check front and rear axle alignment and adjust if out of
specification. specification.
✓ Check steering knuckle to axle beam clearance on MACK FA(W) ✓ Check steering knuckle to axle beam clearance on MACK FA(W)
front axles. front axles.
Initial Valve Lash and Unit Injector Pre-Load Check and Initial Valve Lash and Unit Injector Pre-Load Check and
Adjustment Adjustment
For both highway and vocational usage, an initial valve lash and unit For both highway and vocational usage, an initial valve lash and unit
injector pre-load check and adjustment must be performed at the first injector pre-load check and adjustment must be performed at the first
200 000 km (125,000 miles), 3,400 hours or 12 months of service, 200 000 km (125,000 miles), 3,400 hours or 12 months of service,
whichever occurs first. whichever occurs first.
Your new truck has been quality built, inspected, lubricated and Your new truck has been quality built, inspected, lubricated and
adjusted at the MACK Trucks Assembly Plant. Occasionally, however, adjusted at the MACK Trucks Assembly Plant. Occasionally, however,
an air, oil or coolant leak may develop. Quick action to correct these an air, oil or coolant leak may develop. Quick action to correct these
minor items will prevent a major repair later. Take your truck to the minor items will prevent a major repair later. Take your truck to the
nearest MACK service center as soon as any abnormal condition nearest MACK service center as soon as any abnormal condition
becomes evident. becomes evident.
8 8
Refer to table on page 17 and table on page 20 for the Refer to table on page 17 and table on page 20 for the
recommended lubrication change intervals applicable recommended lubrication change intervals applicable
to the following items: to the following items:
앫 Gear oils — transmission, rear axle carrier(s), 앫 Gear oils — transmission, rear axle carrier(s),
front drive axle carrier, transfer case, flywheel front drive axle carrier, transfer case, flywheel
PTO PTO
앫 Engine oil, oil filters, fuel filters 앫 Engine oil, oil filters, fuel filters
It is important that lubricants, coolants, diesel fuel, It is important that lubricants, coolants, diesel fuel,
etc., meeting proper specifications be used in your etc., meeting proper specifications be used in your
MACK chassis. (Refer to SPECIFICATIONS AND MACK chassis. (Refer to SPECIFICATIONS AND
CAPACITIES.) CAPACITIES.)
When checking oil levels, the vehicle must be parked When checking oil levels, the vehicle must be parked
on level ground, and the units at normal operating on level ground, and the units at normal operating
temperature. Components must be filled to the correct temperature. Components must be filled to the correct
level. DO NOT OVERFILL. level. DO NOT OVERFILL.
The oil and filter change intervals in this manual The oil and filter change intervals in this manual
pertain to components manufactured by Mack Trucks, pertain to components manufactured by Mack Trucks,
Inc. For information concerning oil and oil filter change Inc. For information concerning oil and oil filter change
intervals for vendor components, refer to the specific intervals for vendor components, refer to the specific
vendor component service literature. vendor component service literature.
9 9
DAILY INSPECTION DAILY INSPECTION

Driver’s Daily Inspection Driver’s Daily Inspection
Before beginning the day’s operation, make a “walk around” inspection Before beginning the day’s operation, make a “walk around” inspection
of your truck. The following checklist provides an aid in making a of your truck. The following checklist provides an aid in making a
thorough inspection and ensures no item will be overlooked. Make sure thorough inspection and ensures no item will be overlooked. Make sure
any problem is corrected before using the vehicle. any problem is corrected before using the vehicle.
To avoid serious injury, DO NOT step on fuel tanks, To avoid serious injury, DO NOT step on fuel tanks,
battery boxes, frame, etc. Step only on areas battery boxes, frame, etc. Step only on areas
where adequate slip resistance surfaces and where adequate slip resistance surfaces and
handholds are provided. handholds are provided.
GENERAL APPEARANCE GENERAL APPEARANCE

❒
✓ Check the overall condition of the vehicle. Look for signs of leaking ❒
✓ Check the overall condition of the vehicle. Look for signs of leaking
fuel, oil or coolant. fuel, oil or coolant.
❒
✓ Check to see if the chassis is leaning (flat tires, broken springs, ❒
✓ Check to see if the chassis is leaning (flat tires, broken springs,
etc.). etc.).
❒
✓ Review the previous chassis inspection sheets. Make sure any ❒
✓ Review the previous chassis inspection sheets. Make sure any
reported defects were corrected. reported defects were corrected.
RAISE THE HOOD/TILT THE CAB RAISE THE HOOD/TILT THE CAB
❒
✓ Check the windshield washer reservoir. Add washer solvent if ❒
✓ Check the windshield washer reservoir. Add washer solvent if
necessary. necessary.
Radiator Radiator
❒
✓ Check the coolant level and add a mixture between 40%–60% of ❒
✓ Check the coolant level and add a mixture between 40%–60% of
antifreeze/quality water, if necessary. antifreeze/quality water, if necessary.
✓
❒ Check for coolant leaks. ✓
❒ Check for coolant leaks.
❒
✓ Check the condition of radiator and heater hoses. ❒
✓ Check the condition of radiator and heater hoses.
❒
✓ Clean debris from grille area. ❒
✓ Clean debris from grille area.
10 10
Engine Engine
❒
✓ Check crankcase oil level and add recommended engine oil, if ❒
✓ Check crankcase oil level and add recommended engine oil, if
✓
❒ Check condition of all engine drive belts. ✓
❒ Check condition of all engine drive belts.
❒
✓ Check for oil, fuel and air leaks. ❒
✓ Check for oil, fuel and air leaks.
❒
✓ Check engine and chassis wiring harnesses for frayed or broken ❒
✓ Check engine and chassis wiring harnesses for frayed or broken
wires. wires.
Steering System Steering System

❒
✓ Check power steering fluid level and add recommended fluid, if ❒
✓ Check power steering fluid level and add recommended fluid, if
✓
❒ Check security of steering gear, pitman arm and drag link. ✓
❒ Check security of steering gear, pitman arm and drag link.
❒
✓ Check steering shaft U-joints for tightness, cracks and damage. ❒
✓ Check steering shaft U-joints for tightness, cracks and damage.
CLOSE HOOD/LOWER CAB; SECURE LATCHES CLOSE HOOD/LOWER CAB; SECURE LATCHES
Cab Exterior Cab Exterior
❒
✓ Check condition of wheels and tires. Inspect each tire for cuts, ❒
✓ Check condition of wheels and tires. Inspect each tire for cuts,
leaks, punctures, bulges, abnormal wear and tire match. leaks, punctures, bulges, abnormal wear and tire match.
❒
✓ Check rims for damage and wheel nut tightness. Rust streaks ❒
✓ Check rims for damage and wheel nut tightness. Rust streaks
around wheel nut ball seats are an indication of looseness. around wheel nut ball seats are an indication of looseness.
✓
❒ Check tire pressure while tires are cold. ✓
❒ Check tire pressure while tires are cold.
❒
✓ Check oil level of oil-lubricated front wheel bearings. Add oil, if ❒
✓ Check oil level of oil-lubricated front wheel bearings. Add oil, if
✓
❒ Check brake system components. ✓
❒ Check brake system components.
❒
✓ Check electrolyte level in battery and add distilled water, if ❒
✓ Check electrolyte level in battery and add distilled water, if
necessary. If the battery is a maintenance-free type, check state of necessary. If the battery is a maintenance-free type, check state of
charge indicator. Check the battery cables for condition, chafing charge indicator. Check the battery cables for condition, chafing
and proper routing. and proper routing.
❒
✓ Check condition of fuel tanks and fuel hoses, connectors and ❒
✓ Check condition of fuel tanks and fuel hoses, connectors and
pipes. pipes.
11 11
❒
✓ Inspect air intake for secure mounting, leaks, or damage. Replace ❒
✓ Inspect air intake for secure mounting, leaks, or damage. Replace
air cleaner element if indicator locks in the red zone or air cleaner element if indicator locks in the red zone or
dash-mounted gauge indicates maximum inlet restriction of dash-mounted gauge indicates maximum inlet restriction of
510 mm (20 inches) [MACK] or 635 mm (25 inches) [Cummins] of 510 mm (20 inches) [MACK] or 635 mm (25 inches) [Cummins] of
water for applicable engine (see table on page 113). Gaseous water for applicable engine (see table on page 113). Gaseous
Emission Control Maintenance. Emission Control Maintenance.
❒
✓ Clean headlamps, exterior windows and mirrors. Check windshield ❒
✓ Clean headlamps, exterior windows and mirrors. Check windshield
and mirrors for cracks. Check operation of all lamps and inspect and mirrors for cracks. Check operation of all lamps and inspect
lenses. Repair any non-operating lamps and replace any broken lenses. Repair any non-operating lamps and replace any broken
lenses. lenses.
CLIMB INTO CAB CLIMB INTO CAB

Cab Interior Cab Interior
✓
❒ Clean interior windows and dash gauges. ✓
❒ Clean interior windows and dash gauges.
❒
✓ Check seatbelts for security and damage. ❒
✓ Check seatbelts for security and damage.
❒
✓ Secure any loose items found in the cab. ❒
✓ Secure any loose items found in the cab.
❒
✓ Check emergency equipment and warning devices. ❒
✓ Check emergency equipment and warning devices.
❒
✓ Adjust driver’s seat and sideview mirrors. ❒
✓ Adjust driver’s seat and sideview mirrors.
❒
✓ Check clutch pedal free-play. ❒
✓ Check clutch pedal free-play.
Start the Engine Start the Engine

✓
❒ Listen for any unusual noises. ✓
❒ Listen for any unusual noises.
❒
✓ Make sure the alarms shut off when oil pressure, air pressure, etc., ❒
✓ Make sure the alarms shut off when oil pressure, air pressure, etc.,
reach normal operating range. reach normal operating range.
❒
✓ Check operation of horns (both air and electric), windshield wipers ❒
✓ Check operation of horns (both air and electric), windshield wipers
and washers, heater and defroster, back-up alarm, and, if so and washers, heater and defroster, back-up alarm, and, if so
equipped, heated mirrors. equipped, heated mirrors.
✓
❒ Check operation of service brakes. ✓
❒ Check operation of service brakes.
❒
✓ Check application of parking brakes. ❒
✓ Check application of parking brakes.
12 12
❒
✓ Observe instruments and verify readings. ❒
✓ Observe instruments and verify readings.
— Air pressure gauge — Low air buzzer should shut off at — Air pressure gauge — Low air buzzer should shut off at
483 ± 34 kPa (70 ± 5 psi). Operating range is 724 kPa 483 ± 34 kPa (70 ± 5 psi). Operating range is 724 kPa
(105 psi) minimum to 931 kPa (135 psi) maximum. (105 psi) minimum to 931 kPa (135 psi) maximum.
— Engine oil pressure gauge — MACK MP Engine: 275.8 to — Engine oil pressure gauge — MACK MP Engine: 275.8 to
413.9 kPa (40 to 60 psi) at idle, and 275.8 to 620 kPa (40 to 413.9 kPa (40 to 60 psi) at idle, and 275.8 to 620 kPa (40 to
90 psi) at governed speed. 90 psi) at governed speed.
— Engine oil temperature gauge — MACK MP Engine: — Engine oil temperature gauge — MACK MP Engine:
100°C to 115°C (212°F to 239°F). 100°C to 115°C (212°F to 239°F).
Engine oil pressures and temperatures are for MACK Engine oil pressures and temperatures are for MACK
diesel engines only. Consult specific engine operating diesel engines only. Consult specific engine operating
manual if equipped with an engine other than MACK. manual if equipped with an engine other than MACK.
— Voltmeter — With switch ON and engine OFF, indicates — Voltmeter — With switch ON and engine OFF, indicates
condition of battery. With engine running, indicates condition of battery. With engine running, indicates
condition of charging system. condition of charging system.
— Coolant temperature gauge — Normal operating — Coolant temperature gauge — Normal operating
temperature for MACK MP engines is between 77°C and temperature for MACK MP engines is between 77°C and
104°C (170°F and 220°F). 104°C (170°F and 220°F).
END OF THE DAY END OF THE DAY

❒
✓ Apply parking brakes, block tires and drain water that may have ❒
✓ Apply parking brakes, block tires and drain water that may have
accumulated in the air reservoirs. accumulated in the air reservoirs.
✓
❒ Drain water from fuel separator, if equipped. ✓
❒ Drain water from fuel separator, if equipped.
❒
✓ Check for fuel, oil and coolant leaks. ❒
✓ Check for fuel, oil and coolant leaks.
13 13
PREVENTIVE MAINTENANCE PROGRAM PREVENTIVE MAINTENANCE PROGRAM

MACK Preventive Maintenance and Lubrication Program MACK Preventive Maintenance and Lubrication Program
Your MACK chassis was designed and built with performance, Your MACK chassis was designed and built with performance,
durability and productivity in mind. The MACK Preventive Maintenance durability and productivity in mind. The MACK Preventive Maintenance
and Lubrication program was developed to maintain your chassis and and Lubrication program was developed to maintain your chassis and
keep it running the way it was designed to run. Preventive keep it running the way it was designed to run. Preventive
maintenance, not breakdown maintenance, is the key to many years of maintenance, not breakdown maintenance, is the key to many years of
trouble-free operation. trouble-free operation.
The MACK Preventive Maintenance and Lubrication program consists The MACK Preventive Maintenance and Lubrication program consists
of mechanical inspections, lubrication and oil, filter and coolant of mechanical inspections, lubrication and oil, filter and coolant
conditioner change intervals designed to maintain vehicle efficiency conditioner change intervals designed to maintain vehicle efficiency
and prevent mechanical failure. and prevent mechanical failure.
Developing your maintenance program is not all that complicated, Developing your maintenance program is not all that complicated,
simply choose the maintenance category that best fits your highway or simply choose the maintenance category that best fits your highway or
vocational operation. vocational operation.
The following maintenance categories and interval The following maintenance categories and interval
charts are the standard maintenance and lubrication charts are the standard maintenance and lubrication
intervals for a MACK chassis. intervals for a MACK chassis.
14 14
For ease of planning, maintenance and lubrication schedules are For ease of planning, maintenance and lubrication schedules are
based on mileage/kilometers or days/hours of operation. The service based on mileage/kilometers or days/hours of operation. The service
manager at your MACK dealer will be happy to assist in tailoring a manager at your MACK dealer will be happy to assist in tailoring a
maintenance program for your particular operating requirements. maintenance program for your particular operating requirements.
It is extremely important that engine oil be changed at It is extremely important that engine oil be changed at
the specified oil change intervals as outlined in the the specified oil change intervals as outlined in the
charts found on pages 17 and 20. charts found on pages 17 and 20.
To gain maximum benefit from the MACK Preventive Maintenance To gain maximum benefit from the MACK Preventive Maintenance
Program, Mack Trucks, Inc. recommends the following: Program, Mack Trucks, Inc. recommends the following:
1. Oil and fuel filters must meet MACK specifications and 1. Oil and fuel filters must meet MACK specifications and
should be changed within specified intervals. should be changed within specified intervals.
2. MACK specification EO-O PREMIUM PLUS diesel engine oil 2. MACK specification EO-O PREMIUM PLUS diesel engine oil
is mandatory. is mandatory.
3. MACK specification Grade 2D Ultra Low Sulfur Diesel (ULSD) 3. MACK specification Grade 2D Ultra Low Sulfur Diesel (ULSD)
fuel must be used. fuel must be used.
4. MACK factory specifications must be maintained. 4. MACK factory specifications must be maintained.
Diesel engines used in 2007 and later model year Diesel engines used in 2007 and later model year
vehicles are designed to operate with Ultra Low Sulfur vehicles are designed to operate with Ultra Low Sulfur
Diesel (ULSD) fuel only. Usage of improper diesel fuel Diesel (ULSD) fuel only. Usage of improper diesel fuel
will reduce engine efficiency and durability, will reduce engine efficiency and durability,
permanently damage advanced emission control permanently damage advanced emission control
devices, reduce fuel economy and possibly prevent devices, reduce fuel economy and possibly prevent
the engine from running. Manufacturer’s warranties the engine from running. Manufacturer’s warranties
may be voided due to usage of improper fuel, and may be voided due to usage of improper fuel, and
using low sulfur in 2007 and later diesel-powered cars, using low sulfur in 2007 and later diesel-powered cars,
trucks and buses violates Federal emissions laws and trucks and buses violates Federal emissions laws and
is punishable with civil penalties. is punishable with civil penalties.
15 15
Certain chassis vocations may require more frequent Certain chassis vocations may require more frequent
service intervals. When developing a maintenance service intervals. When developing a maintenance
program, review chassis operating conditions and program, review chassis operating conditions and
adjust the service intervals as required. At each adjust the service intervals as required. At each
maintenance and lubrication interval, look at the maintenance and lubrication interval, look at the
condition of chassis lubrication points, condition of condition of chassis lubrication points, condition of
components, etc., and adjust your service intervals components, etc., and adjust your service intervals
accordingly. accordingly.
A lubricant analysis program performed by a reputable A lubricant analysis program performed by a reputable
laboratory is the most effective method of determining laboratory is the most effective method of determining
lubricant change intervals. Mack Trucks, Inc., supports lubricant change intervals. Mack Trucks, Inc., supports
the Maxigard/2 Oil Analysis Program which is the Maxigard/2 Oil Analysis Program which is
conducted by Analysts, Inc. Test kits are available conducted by Analysts, Inc. Test kits are available
through MACK Parts System. Part Nos. for the various through MACK Parts System. Part Nos. for the various
test kits are as follows: test kits are as follows:
앫 4549-PMXBB — Tests spectrochemical, LEM (to 앫 4549-PMXBB — Tests spectrochemical, LEM (to
determine soot levels), fuel dilution, viscosity and determine soot levels), fuel dilution, viscosity and
neutralization (known as TBN), uses a plastic neutralization (known as TBN), uses a plastic
bellows-type container for collecting the oil bellows-type container for collecting the oil
sample sample
앫 4549-PMXBJ — Tests spectrochemical, LEM (to 앫 4549-PMXBJ — Tests spectrochemical, LEM (to
determine soot levels), fuel dilution, viscosity and determine soot levels), fuel dilution, viscosity and
neutralization (known as TBN), uses a jar for neutralization (known as TBN), uses a jar for
collecting the oil sample collecting the oil sample
For additional information, contact Analysts, Inc. at For additional information, contact Analysts, Inc. at
1-800-655-4473, or visit their website at 1-800-655-4473, or visit their website at
www.analystsinc.com. www.analystsinc.com.
Alter the maintenance program to meet your needs, Alter the maintenance program to meet your needs,
but never exceed MACK-recommended intervals. but never exceed MACK-recommended intervals.
1 1
16 16

MP7 AND MP8 ENGINE MAINTENANCE MP7 AND MP8 ENGINE MAINTENANCE
MEDIUM HIGHWAY HEAVY HIGHWAY MEDIUM HIGHWAY HEAVY HIGHWAY
USAGE USAGE USAGE USAGE
Total Fuel Consumption Total Fuel Consumption Total Fuel Consumption Total Fuel Consumption
Less than 39 L/km Less than 50 L/km Less than 39 L/km Less than 50 L/km
(Greater than 6.0 MPG) (Greater than 4.7 MPG) (Greater than 6.0 MPG) (Greater than 4.7 MPG)
Oil and Filter Change 56 000 km/ 40 000 km/ Oil and Filter Change 56 000 km/ 40 000 km/
(includes fuel filters) 35,000 miles 25,000 miles (includes fuel filters) 35,000 miles 25,000 miles
Note: If idle time is Note: If idle time is
greater than 25% of greater than 25% of
total vehicle usage, use total vehicle usage, use
the next lower drain the next lower drain
interval. interval.
Air Filter At maximum restriction as indicated on gauge, or Air Filter At maximum restriction as indicated on gauge, or
12 months, whichever occurs first 12 months, whichever occurs first
Coolant Conditioner 80 000 km/50,000 miles Coolant Conditioner 80 000 km/50,000 miles
(used with traditional (the coolant conditioner may be changed at each oil (used with traditional (the coolant conditioner may be changed at each oil
coolants requiring and filter change interval) coolants requiring and filter change interval)
Supplemental Coolant Supplemental Coolant
Additive [SCA]) Additive [SCA])
Coolant Filter (used with 240 000 km/150,000 miles* or 12 months* Coolant Filter (used with 240 000 km/150,000 miles* or 12 months*
extended-life coolants extended-life coolants
which do not require which do not require
SCA) SCA)
Coolant Traditional — (fully formulated) 500 000 km/ Coolant Traditional — (fully formulated) 500 000 km/
300,000 miles* or 24 months* 300,000 miles* or 24 months*
Extended-Life — 1 000 000 km/600,000 miles* or Extended-Life — 1 000 000 km/600,000 miles* or
48 months* 48 months*
Valve Lash and Unit Initial — 200 000 km/125,000 miles* or 12 months* Valve Lash and Unit Initial — 200 000 km/125,000 miles* or 12 months*
Injector Pre-Load Check Regular — 400 000 km/250,000 miles* or 24 months* Injector Pre-Load Check Regular — 400 000 km/250,000 miles* or 24 months*
and Adjustment and Adjustment
Belts (Fan and 500 000 km/300,000 miles* or maximum of Belts (Fan and 500 000 km/300,000 miles* or maximum of
Accessory) 36 months* Accessory) 36 months*
Ash Cleaning (Catalyzed 400 000 km/250,000 miles* or 4,500 hours* Ash Cleaning (Catalyzed 400 000 km/250,000 miles* or 4,500 hours*
Diesel Particulate Filter Diesel Particulate Filter
[DPF]) [DPF])
Aftertreatment 240 000 km/150,000 miles* or 4,500 hours* Aftertreatment 240 000 km/150,000 miles* or 4,500 hours*
Hydrocarbon Injector Hydrocarbon Injector
(AHI) Service (AHI) Service
*Whichever occurs first. *Whichever occurs first.
17 17

CHASSIS MAINTENANCE AND LUBRICATION CHASSIS MAINTENANCE AND LUBRICATION

MEDIUM HIGHWAY HEAVY HIGHWAY MEDIUM HIGHWAY HEAVY HIGHWAY
USAGE USAGE USAGE USAGE
A Inspection 26 000 km/ 20 000 km/ A Inspection 26 000 km/ 20 000 km/
17,500 miles 12,500 miles 17,500 miles 12,500 miles
B Inspection 56 000 km/ 40 000 km/ B Inspection 56 000 km/ 40 000 km/
C Inspection 112 000 km/ 80 000 km/ C Inspection 112 000 km/ 80 000 km/
D Inspection 225 000 km/ 161 000 km/ D Inspection 225 000 km/ 161 000 km/
Chassis Lubrication 26 000 km/ 20 000 km/ Chassis Lubrication 26 000 km/ 20 000 km/
(Note 1) 17,500 miles 12,500 miles (Note 1) 17,500 miles 12,500 miles
Gear Oil Change 402 000 km/250,000 miles* or 2 years* Gear Oil Change 402 000 km/250,000 miles* or 2 years*
(Note 2) (Note 2)
18 18
Certain chassis vocations may require more frequent Certain chassis vocations may require more frequent
service intervals. When developing a maintenance service intervals. When developing a maintenance
program, review chassis operating conditions and program, review chassis operating conditions and
adjust the service intervals as required. At each adjust the service intervals as required. At each
maintenance and lubrication interval, look at the maintenance and lubrication interval, look at the
condition of chassis lubrication points, condition of condition of chassis lubrication points, condition of
components, etc., and adjust your service intervals components, etc., and adjust your service intervals
accordingly. Using a lubricant analysis program accordingly. Using a lubricant analysis program
performed by a reputable laboratory is the most performed by a reputable laboratory is the most
effective method of determining lubricant change effective method of determining lubricant change
intervals. Alter the maintenance program to meet your intervals. Alter the maintenance program to meet your
needs, but never exceed MACK recommended needs, but never exceed MACK recommended
intervals. intervals.
19 19
2 2

SEVERE VOCATIONAL VERY SEVERE SEVERE VOCATIONAL VERY SEVERE

USAGE VOCATIONAL USAGE USAGE VOCATIONAL USAGE
Less than 64 MPG Less than 120 L/km Less than 64 MPG Less than 120 L/km
Oil and Filter Change 24 000 km/15,000 miles*, 16 000 km/10,000 miles*, Oil and Filter Change 24 000 km/15,000 miles*, 16 000 km/10,000 miles*,
(includes fuel filters) 450 hours* or 6 months 300 hours* or 6 months (includes fuel filters) 450 hours* or 6 months 300 hours* or 6 months
Note: If idle time is maximum* maximum* Note: If idle time is maximum* maximum*
greater than 25% of greater than 25% of
total vehicle usage, use total vehicle usage, use
the next lower drain the next lower drain
interval. interval.
Air Filter At maximum restriction as indicated on gauge, or Air Filter At maximum restriction as indicated on gauge, or
Coolant Conditioner 80 000 km/50,000 miles* or 6 months* Coolant Conditioner 80 000 km/50,000 miles* or 6 months*
(used with traditional (used with traditional
coolants requiring coolants requiring
Supplemental Coolant Supplemental Coolant
Additive [SCA]) Additive [SCA])
Coolant Filter (used with 240 000 km/150,000 miles* or 12 months* Coolant Filter (used with 240 000 km/150,000 miles* or 12 months*
extended-life coolants extended-life coolants
which do not require which do not require
SCA) SCA)
Coolant Traditional — (fully formulated) 500 000 km/ Coolant Traditional — (fully formulated) 500 000 km/
300,000 miles* or 24 months* 300,000 miles* or 24 months*
Extended-Life — 1 000 000 km/600,000 miles* or Extended-Life — 1 000 000 km/600,000 miles* or
48 months* 48 months*
20 20


Less than 64 MPG Less than 120 L/km Less than 64 MPG Less than 120 L/km
Valve Lash and Unit Initial — 200 000 km/125,000 miles* or 12 months* Valve Lash and Unit Initial — 200 000 km/125,000 miles* or 12 months*
Injector Pre-Load Check Regular — 400 000 km/250,000 miles* or 24 months* Injector Pre-Load Check Regular — 400 000 km/250,000 miles* or 24 months*
and Adjustment and Adjustment
Belts (Fan and 240 000 km/150,000 miles* or maximum of 12 months* Belts (Fan and 240 000 km/150,000 miles* or maximum of 12 months*
Accessory) Accessory)
Ash Cleaning (Catalyzed 400 000 km/250,000 miles* or 4,500 hours* Ash Cleaning (Catalyzed 400 000 km/250,000 miles* or 4,500 hours*
and Non-Catalyzed and Non-Catalyzed
Diesel Particulate Filter Diesel Particulate Filter
[DPF]) [DPF])
Aftertreatment 240 000 km/150,000 miles* or 4,500 hours* Aftertreatment 240 000 km/150,000 miles* or 4,500 hours*
Hydrocarbon Injector Hydrocarbon Injector
(AHI) cleaning (catalyzed (AHI) cleaning (catalyzed
only) only)
Electrode and Injection 161 000 km/100,000 miles* or 2,400 hours* Electrode and Injection 161 000 km/100,000 miles* or 2,400 hours*
Nozzle Service Nozzle Service
(non-catalyzed DPF only) (non-catalyzed DPF only)
21 21

CHASSIS MAINTENANCE AND LUBRICATION CHASSIS MAINTENANCE AND LUBRICATION

A Inspection 12 000 km/ 8 000 km/ A Inspection 12 000 km/ 8 000 km/
7,500 miles* 5,000 miles* 7,500 miles* 5,000 miles*
or 225 hours* or 150 hours* or 225 hours* or 150 hours*
B Inspection 24 000 km/ 16 000 km/ B Inspection 24 000 km/ 16 000 km/
C Inspection 48 000 km/ 32 000 km/ C Inspection 48 000 km/ 32 000 km/
D Inspection 96 000 km/ 64 000 km/ D Inspection 96 000 km/ 64 000 km/
or 1,800 hours* or 1,200 hours* or 1,800 hours* or 1,200 hours*
Chassis Lubrication 12 000 km/ 8 000 km/ Chassis Lubrication 12 000 km/ 8 000 km/
(Note 1) 7,500 miles 5,000 miles* (Note 1) 7,500 miles 5,000 miles*
Gear Oil Change 64 000 km/40,000 miles* 1 year* or 1,200 hours Gear Oil Change 64 000 km/40,000 miles* 1 year* or 1,200 hours
(Note 2) (Note 2)
22 22
NOTES TABLE NOTES TABLE
Note 1: Lubricate the clutch release bearing at each recommended Note 1: Lubricate the clutch release bearing at each recommended
chassis lubrication interval (refer to the interval charts on chassis lubrication interval (refer to the interval charts on
pages 17 through 20). pages 17 through 20).
Lubricate the driveshaft (Spicer and ArvinMeritor™) at the Lubricate the driveshaft (Spicer and ArvinMeritor™) at the
following intervals: following intervals:
Spicer Life™ SPL-170 and SPL-250 Driveshaft — U-Joint Spicer Life™ SPL-170 and SPL-250 Driveshaft — U-Joint
Lubrication Lubrication
앫 Highway Usage: Every 161 000 km (100,000 miles) or 앫 Highway Usage: Every 161 000 km (100,000 miles) or
6 months* 6 months*
앫 Vocational Usage: 앫 Vocational Usage:
— Severe Vocational Usage: 32 000 km — Severe Vocational Usage: 32 000 km
(20,000 miles) or 180 days* (20,000 miles) or 180 days*
— Very Severe Vocational Usage: 375 hours or — Very Severe Vocational Usage: 375 hours or
90 days* 90 days*
* Whichever occurs first. * Whichever occurs first.
23 23
Spicer Life™ SPL-170XL and SPL-250XL Driveshaft — Spicer Life™ SPL-170XL and SPL-250XL Driveshaft —
U-Joint Lubrication U-Joint Lubrication
Spicer Life™ XL series driveshafts are equipped with Spicer Life™ XL series driveshafts are equipped with
“extended-lubrication” U-joints. These U-joints are easily “extended-lubrication” U-joints. These U-joints are easily
identified by the blue plastic cover in the center of the U-joint identified by the blue plastic cover in the center of the U-joint
cross where the grease fitting is usually located. The XL cross where the grease fitting is usually located. The XL
U-joints must be lubricated initially at the following intervals: U-joints must be lubricated initially at the following intervals:
앫 Highway Chassis: 560 000 km (350,000 miles) or 앫 Highway Chassis: 560 000 km (350,000 miles) or
3 years* 3 years*
앫 Vocational Chassis (includes city driving and on/off 앫 Vocational Chassis (includes city driving and on/off
highway: 161 000 km (100,000 miles) or 1 year* highway: 161 000 km (100,000 miles) or 1 year*
Following the initial lubrication outlined above, Spicer Life™ Following the initial lubrication outlined above, Spicer Life™
XL series U-joints must be lubricated at the following XL series U-joints must be lubricated at the following
intervals: intervals:
앫 Highway Chassis: 161 000 km (100,000 miles) or 앫 Highway Chassis: 161 000 km (100,000 miles) or
6 months* 6 months*
앫 Vocational Chassis: 앫 Vocational Chassis:
— Severe Service: 32 000 km (20,000 miles) or — Severe Service: 32 000 km (20,000 miles) or
180 days* 180 days*
— Extra Severe Service: 375 hours or 90 days* — Extra Severe Service: 375 hours or 90 days*
The slip-joints used with Spicer Life™ driveshafts The slip-joints used with Spicer Life™ driveshafts
are “Lubed for Life,” and protected by a bellows. are “Lubed for Life,” and protected by a bellows.
Lubrication of these slip-joints is not required and Lubrication of these slip-joints is not required and
the bellows must not be disturbed. the bellows must not be disturbed.
ArvinMeritor™ RPL20 and RPL25 Permalube™ Series ArvinMeritor™ RPL20 and RPL25 Permalube™ Series
Driveshafts Driveshafts
The U-joints and slip joints on the RPL20 and RPL25 series The U-joints and slip joints on the RPL20 and RPL25 series
driveshafts are permanently lubricated and sealed. driveshafts are permanently lubricated and sealed.
Lubrication at regular intervals is not required during the life Lubrication at regular intervals is not required during the life
of the driveshaft. of the driveshaft.
24 24
ArvinMeritor™ 92N Permalube™ Wing-Style Driveshafts ArvinMeritor™ 92N Permalube™ Wing-Style Driveshafts
The U-joints used on the 92N Permalube™ Wing-Style The U-joints used on the 92N Permalube™ Wing-Style
Driveshafts are permanently lubricated and sealed. Driveshafts are permanently lubricated and sealed.
Lubrication at regular intervals is not required during the life Lubrication at regular intervals is not required during the life
of the driveshaft. The slip joints, however, must be lubricated of the driveshaft. The slip joints, however, must be lubricated
at each specified chassis lubrication interval. Refer to the at each specified chassis lubrication interval. Refer to the
preventive maintenance schedules found on pages 17 preventive maintenance schedules found on pages 17
and 20. and 20.
Note 2: An extended service drain interval of 804 600 km Note 2: An extended service drain interval of 804 600 km
(500,000 miles) or 3 years, whichever occurs first, for (500,000 miles) or 3 years, whichever occurs first, for
Highway type operations is permissible for MACK geared Highway type operations is permissible for MACK geared
drivetrain components (Transmissions and Carriers) IF drivetrain components (Transmissions and Carriers) IF
MACK-specific GO-J PLUS Gear Lubricant is used. For MACK-specific GO-J PLUS Gear Lubricant is used. For
Vocational operations, an extended drain interval of Vocational operations, an extended drain interval of
128 800 km (80,000 miles), 1 year or 1,200 hours, whichever 128 800 km (80,000 miles), 1 year or 1,200 hours, whichever
occurs first, is permissible if GO-J PLUS Gear Lubricant is occurs first, is permissible if GO-J PLUS Gear Lubricant is
used. An SAE 40 or 50 grade transmission oil, TO-A PLUS, is used. An SAE 40 or 50 grade transmission oil, TO-A PLUS, is
also available for use in all MACK transmissions. Extended also available for use in all MACK transmissions. Extended
drain intervals for transmissions using TO-A PLUS are drain intervals for transmissions using TO-A PLUS are
804 600 km (500,000 miles) or 3 years, whichever occurs 804 600 km (500,000 miles) or 3 years, whichever occurs
first, for Highway operations, and 128 800 km (80,000 miles), first, for Highway operations, and 128 800 km (80,000 miles),
1 year or 1,200 hours, whichever occurs first, for Vocational 1 year or 1,200 hours, whichever occurs first, for Vocational
operations. operations.
If a MACK axle and/or transmission were initially If a MACK axle and/or transmission were initially
filled with GO-J PLUS gear lubricant and later filled with GO-J PLUS gear lubricant and later
“topped-off” with greater than 1-1/2 quarts of GO-J “topped-off” with greater than 1-1/2 quarts of GO-J
specification gear lubricant, the drain interval is specification gear lubricant, the drain interval is
reduced to the GO-J limits (2 years or 402 300 km reduced to the GO-J limits (2 years or 402 300 km
[250,000 miles]). [250,000 miles]).
25 25
For chassis equipped with Eaton Fuller transmissions and For chassis equipped with Eaton Fuller transmissions and
Eaton drive axles, Eaton-specified extended drain interval Eaton drive axles, Eaton-specified extended drain interval
lubricants (E250 and E500) are available. E250 has a lubricants (E250 and E500) are available. E250 has a
400 000 km (250,000-mile) drain interval requirement and 400 000 km (250,000-mile) drain interval requirement and
E500 has an 800 000 km (500,000-mile) drain interval E500 has an 800 000 km (500,000-mile) drain interval
requirement whether these lubricants were “factory filled” or requirement whether these lubricants were “factory filled” or
“service filled.” For a list of Eaton-approved extended drain “service filled.” For a list of Eaton-approved extended drain
interval lubricants, contact an Eaton service representative, interval lubricants, contact an Eaton service representative,
or visit the Eaton website at www.eaton.com. or visit the Eaton website at www.eaton.com.
Note that transmission and drive axle lubricants for Eaton Note that transmission and drive axle lubricants for Eaton
components are different. Be sure the proper lubricant is components are different. Be sure the proper lubricant is
being used in the component. being used in the component.
“Service fill” is defined as anytime a component is drained “Service fill” is defined as anytime a component is drained
and re-filled with lubricant. This applies whether an approved and re-filled with lubricant. This applies whether an approved
extended drain interval lubricant is drained and the extended drain interval lubricant is drained and the
component is refilled with an approved extended drain component is refilled with an approved extended drain
interval lubricant, or a petroleum-based lubricant is drained interval lubricant, or a petroleum-based lubricant is drained
and the component is refilled with an extended drain interval and the component is refilled with an extended drain interval
lubricant. “Factory fill” is defined as when the component is lubricant. “Factory fill” is defined as when the component is
filled with lubricant at the assembly plant. filled with lubricant at the assembly plant.
If an Eaton Fuller transmission or Eaton drive axle is If an Eaton Fuller transmission or Eaton drive axle is
“factory filled” with a petroleum-based lubricant, and it is “factory filled” with a petroleum-based lubricant, and it is
desired to change to an approved extended drain interval desired to change to an approved extended drain interval
lubricant, it is recommended that this be done within the first lubricant, it is recommended that this be done within the first
8 000 km (5,000 miles) of service. If this cannot be done, it is 8 000 km (5,000 miles) of service. If this cannot be done, it is
important that seals be checked for leaks, and they be important that seals be checked for leaks, and they be
replaced if they are leaking. Seal performance can be replaced if they are leaking. Seal performance can be
jeopardized if an approved extended drain lubricant is used jeopardized if an approved extended drain lubricant is used
as a “service fill” for a component that has been “factory filled” as a “service fill” for a component that has been “factory filled”
with a petroleum-base lubricant. with a petroleum-base lubricant.
Oil changes, filter changes and chassis lubrication Oil changes, filter changes and chassis lubrication
intervals listed in this publication are specifically for intervals listed in this publication are specifically for
chassis equipped with MACK components. For oil and chassis equipped with MACK components. For oil and
filter change information concerning vendor filter change information concerning vendor
components (transmissions, axles, etc.), consult the components (transmissions, axles, etc.), consult the
specific vendor component service literature. specific vendor component service literature.
26 26
Preventive Maintenance Inspection Instructions Preventive Maintenance Inspection Instructions

The MACK Preventive Maintenance Program is arranged in The MACK Preventive Maintenance Program is arranged in
easy-to-follow steps. Inspections are arranged in A, B, C, D order: easy-to-follow steps. Inspections are arranged in A, B, C, D order:
“A” is a light inspection. “A” is a light inspection.
“B” is a more detailed check. “B” is a more detailed check.
“C” is a more extensive inspection and adjustment. “C” is a more extensive inspection and adjustment.
“D” is a comprehensive inspection and adjustment. “D” is a comprehensive inspection and adjustment.
“L” is a chassis lubrication. “L” is a chassis lubrication.
Perform a road test before each inspection to determine the road Perform a road test before each inspection to determine the road
worthiness of the vehicle and isolate any specific problems. worthiness of the vehicle and isolate any specific problems.
Preventive maintenance inspection worksheets A, B, C and D are Preventive maintenance inspection worksheets A, B, C and D are
available through your MACK dealer, and provide a convenient means available through your MACK dealer, and provide a convenient means
of keeping track of the maintenance procedures. of keeping track of the maintenance procedures.
Form No. TS491 A & B covers schedules A and B. Form No. TS491 A & B covers schedules A and B.
Form No. TS491 C & D covers schedules C and D. Form No. TS491 C & D covers schedules C and D.
Order a supply now so you will have them when needed. Order a supply now so you will have them when needed.
For specific questions concerning service, maintenance and lubrication For specific questions concerning service, maintenance and lubrication
procedures not covered in this manual, or for components not procedures not covered in this manual, or for components not
manufactured by Mack Trucks, Inc., refer to the appropriate section of manufactured by Mack Trucks, Inc., refer to the appropriate section of
the operator’s manual, service manual or vendor service publications, the operator’s manual, service manual or vendor service publications,
or consult your MACK dealer. or consult your MACK dealer.
After performing the operations as listed and noting any adjustments, After performing the operations as listed and noting any adjustments,
repairs and replacements on the applicable inspection form, the repairs and replacements on the applicable inspection form, the
completed form should be signed by the technician and foreman (or completed form should be signed by the technician and foreman (or
inspector) and filed in the chassis folder. inspector) and filed in the chassis folder.
27 27
NOISE EMISSION CONTROL NOISE EMISSION CONTROL

Noise Emission Information Noise Emission Information
Specific maintenance procedures performed at regularly scheduled Specific maintenance procedures performed at regularly scheduled
intervals are necessary for maintaining noise emissions within intervals are necessary for maintaining noise emissions within
acceptable limits throughout the life of the vehicle. This manual acceptable limits throughout the life of the vehicle. This manual
includes written instructions pertaining to maintenance items which are includes written instructions pertaining to maintenance items which are
required to maintain the efficiency of the noise emission control required to maintain the efficiency of the noise emission control
systems. systems.
Explanations of maintenance items for noise emission-related Explanations of maintenance items for noise emission-related
components are outlined in “CHASSIS INSPECTION” on page 36, components are outlined in “CHASSIS INSPECTION” on page 36,
along with schedules at which each item must be serviced. Noise along with schedules at which each item must be serviced. Noise
emission-related maintenance items are noted as such for easy emission-related maintenance items are noted as such for easy
reference. The Preventive Maintenance Schedule charts outline the reference. The Preventive Maintenance Schedule charts outline the
MACK recommended time or mileage intervals between service MACK recommended time or mileage intervals between service
schedules. schedules.
Mack Trucks, Inc. recommends that copies of all work orders, invoices Mack Trucks, Inc. recommends that copies of all work orders, invoices
and other pertinent information relating to vehicle maintenance be kept and other pertinent information relating to vehicle maintenance be kept
on file for later reference. A service log can be found at the end of this on file for later reference. A service log can be found at the end of this
manual that provides a convenient place for maintaining a record of manual that provides a convenient place for maintaining a record of
service work performed on the chassis. Service records, along with this service work performed on the chassis. Service records, along with this
manual, should be passed along to subsequent owners of the vehicle. manual, should be passed along to subsequent owners of the vehicle.
The following information concerning noise emission control systems The following information concerning noise emission control systems
requirements is provided to familiarize the ultimate purchaser of this requirements is provided to familiarize the ultimate purchaser of this
vehicle with his responsibilities as the owner, as well as the vehicle with his responsibilities as the owner, as well as the
responsibilities of Mack Trucks, Inc. as the manufacturer. responsibilities of Mack Trucks, Inc. as the manufacturer.
28 28
Noise Emission Control Systems Noise Emission Control Systems

United States Environmental Protection Agency (EPA) regulations United States Environmental Protection Agency (EPA) regulations
require that vehicle manufacturers provide written instructions for the require that vehicle manufacturers provide written instructions for the
proper maintenance, use and repair of the vehicle to the ultimate proper maintenance, use and repair of the vehicle to the ultimate
purchaser to provide reasonable assurance of the elimination or purchaser to provide reasonable assurance of the elimination or
minimization of noise emission degradation throughout the life of the minimization of noise emission degradation throughout the life of the
vehicle. This manual covers items of maintenance which are necessary vehicle. This manual covers items of maintenance which are necessary
to maintain noise emission control efficiency. to maintain noise emission control efficiency.
Tampering with Noise Control Systems is Prohibited Tampering with Noise Control Systems is Prohibited
Among those acts presumed to constitute tampering are those acts Among those acts presumed to constitute tampering are those acts
listed below: listed below:
앫 Removal, or rendering inoperative, of any exhaust components, 앫 Removal, or rendering inoperative, of any exhaust components,
including mufflers, heavy or double-wall exhaust tubing, flexible including mufflers, heavy or double-wall exhaust tubing, flexible
tubing or exhaust pipe clamping. tubing or exhaust pipe clamping.
앫 Removal, or rendering inoperative, of the temperature-modulated 앫 Removal, or rendering inoperative, of the temperature-modulated
cooling fan system. cooling fan system.
앫 Removal of the cooling fan shroud. 앫 Removal of the cooling fan shroud.
앫 Removal, or rendering inoperative, of the air cleaner or air intake 앫 Removal, or rendering inoperative, of the air cleaner or air intake
in-line silencer. in-line silencer.
앫 Removal of the sound deadening material from the hood or cab 앫 Removal of the sound deadening material from the hood or cab
tunnel. tunnel.
앫 Removal, or rendering inoperative, of the engine speed governor 앫 Removal, or rendering inoperative, of the engine speed governor
so as to allow engine speed to exceed the manufacturer’s so as to allow engine speed to exceed the manufacturer’s
specifications. specifications.
앫 Removal of splash shields located inside the wheel housings. 앫 Removal of splash shields located inside the wheel housings.
앫 Removal of engine block shields. 앫 Removal of engine block shields.
앫 Removal of engine crankcase shields or insulation. 앫 Removal of engine crankcase shields or insulation.
앫 Removal of insulated rocker arm covers. 앫 Removal of insulated rocker arm covers.
앫 Removal of transmission noise shields. 앫 Removal of transmission noise shields.
29 29
Vehicle Identification Number (VIN) and Model Year Vehicle Identification Number (VIN) and Model Year
Designation Designation
U.S. and Canadian motor-vehicle safety standards require that each U.S. and Canadian motor-vehicle safety standards require that each
chassis manufactured by Mack Trucks, Inc. be identified by a chassis manufactured by Mack Trucks, Inc. be identified by a
17-character Vehicle Identification Number (VIN). The VIN can be 17-character Vehicle Identification Number (VIN). The VIN can be
found at several locations on the chassis. Refer to the Operator’s found at several locations on the chassis. Refer to the Operator’s
Handbook for exact locations. Handbook for exact locations.
The 10th digit of the Vehicle Identification Number identifies the The 10th digit of the Vehicle Identification Number identifies the
chassis model year. Listed below is a sample VIN with the model year chassis model year. Listed below is a sample VIN with the model year
designation highlighted, along with a chart explaining the model year designation highlighted, along with a chart explaining the model year
code. code.
3 3

Figure 3 — Sample VIN and Model Year Code Figure 3 — Sample VIN and Model Year Code
30 30
ROAD TEST ROAD TEST
ROAD TEST ROAD TEST

Before proceeding with the chassis inspections, a road test should be Before proceeding with the chassis inspections, a road test should be
performed to determine the road worthiness of the vehicle and to performed to determine the road worthiness of the vehicle and to
isolate any specific problems. isolate any specific problems.
ENGINE: Inspection ENGINE: Inspection
Schedule Schedule
Check operation of engine alarm(s) and shutdown A, B, C, D Check operation of engine alarm(s) and shutdown A, B, C, D
system. The alarms should operate when the key system. The alarms should operate when the key
switch is turned ON, before the engine is started, switch is turned ON, before the engine is started,
and should shut off when oil pressure, air pressure, and should shut off when oil pressure, air pressure,
etc., reach operating range. The electronic etc., reach operating range. The electronic
malfunction lamp should turn off approximately two malfunction lamp should turn off approximately two
seconds after the engine starts. If the alarms fail to seconds after the engine starts. If the alarms fail to
function in this test or other malfunctions are noted, function in this test or other malfunctions are noted,
repair as necessary. repair as necessary.
Check the operation of the starter drive mechanism A, B, C, D Check the operation of the starter drive mechanism A, B, C, D
(positive action, no unusual noises). (positive action, no unusual noises).
Check for rough idling, misfiring, bearing noises, A, B, C, D Check for rough idling, misfiring, bearing noises, A, B, C, D
piston slap and knock. piston slap and knock.
Check for unusual exhaust. Note the color and A, B, C, D Check for unusual exhaust. Note the color and A, B, C, D
intensity of the smoke. intensity of the smoke.
Record oil pressure kPa (psi) at idle and governed A, B, C, D Record oil pressure kPa (psi) at idle and governed A, B, C, D
speeds (engine at operating temperature). speeds (engine at operating temperature).
Check voltmeter and record maximum voltage A, B, C, D Check voltmeter and record maximum voltage A, B, C, D
reading. reading.
Check and record engine coolant temperature in A, B, C, D Check and record engine coolant temperature in A, B, C, D
degrees C° (F°) after engine has achieved degrees C° (F°) after engine has achieved
operating temperature. operating temperature.
If the engine is equipped with an engine oil A, B, C, D If the engine is equipped with an engine oil A, B, C, D
temperature gauge, check and record the oil temperature gauge, check and record the oil
temperature in degrees C° (F°) after the engine has temperature in degrees C° (F°) after the engine has
achieved operating temperature. achieved operating temperature.
31 31
ROAD TEST ROAD TEST

(continued) Schedule (continued) Schedule
Check tachometer operation throughout engine A, B, C, D Check tachometer operation throughout engine A, B, C, D
speed range. Note any unsteady pointer operation. speed range. Note any unsteady pointer operation.
Check speedometer operation while driving vehicle. A, B, C, D Check speedometer operation while driving vehicle. A, B, C, D
Note accuracy and any unsteady pointer operation. Note accuracy and any unsteady pointer operation.
Check operation of exhaust pyrometer. A, B, C, D Check operation of exhaust pyrometer. A, B, C, D
AIR COMPRESSOR: AIR COMPRESSOR:
Check for proper operation. Build-up time of air A, B, C, D Check for proper operation. Build-up time of air A, B, C, D
pressure from 586 to 690 kPa (85 to 100 psi) should pressure from 586 to 690 kPa (85 to 100 psi) should
not exceed 25 seconds with engine running at not exceed 25 seconds with engine running at
maximum governed no-load speed. Rapidly cycle maximum governed no-load speed. Rapidly cycle
brake treadle valve until reservoir pressure drops brake treadle valve until reservoir pressure drops
below 724 kPa (105 psi). Note and record pressure below 724 kPa (105 psi). Note and record pressure
at which governor cuts in. at which governor cuts in.
Governor should cutout when reservoir pressure A, B, C, D Governor should cutout when reservoir pressure A, B, C, D
reaches 862–931 kPa (125–135 psi). Note and reaches 862–931 kPa (125–135 psi). Note and
record pressure at which the governor cuts out. record pressure at which the governor cuts out.
Check operation of low air pressure indicators, both Check operation of low air pressure indicators, both
low air pressure indicator light and audible low-air low air pressure indicator light and audible low-air
buzzer. buzzer.
CLUTCH: CLUTCH:
Check clutch pedal free travel. Do not allow less A, B, C, D Check clutch pedal free travel. Do not allow less A, B, C, D
than 1/2 inch of free travel. Adjust to specifications, than 1/2 inch of free travel. Adjust to specifications,
if necessary. (See “CLUTCH ADJUSTMENT” on if necessary. (See “CLUTCH ADJUSTMENT” on
page 247.) page 247.)
Check clutch release when chassis is stopped and A, B, C, D Check clutch release when chassis is stopped and A, B, C, D
the engine is running at low idle. Verify proper the engine is running at low idle. Verify proper
clutch brake operation. Increased pedal effort clutch brake operation. Increased pedal effort
should be felt approximately 6.35–9.53 mm (1/4 to should be felt approximately 6.35–9.53 mm (1/4 to
3/8 inch) from end of clutch pedal travel when pedal 3/8 inch) from end of clutch pedal travel when pedal
is depressed fully. is depressed fully.
32 32
ROAD TEST ROAD TEST
STEERING: Inspection STEERING: Inspection

Schedule Schedule
Check for bind in steering — Bind may be caused A, B, C, D Check for bind in steering — Bind may be caused A, B, C, D
by inadequate lubrication or worn steering or by inadequate lubrication or worn steering or
steering axle components. steering axle components.
Check for excessive free play in steering — Free A, B, C, D Check for excessive free play in steering — Free A, B, C, D
play may be caused by excessive steering gear play may be caused by excessive steering gear
backlash or loose steering linkage. backlash or loose steering linkage.
Check for wander — Wander may be caused by A, B, C, D Check for wander — Wander may be caused by A, B, C, D
insufficient or unequal caster, camber, inadequate insufficient or unequal caster, camber, inadequate
lubrication or excessively worn steering or axle lubrication or excessively worn steering or axle
components. components.
Check for shimmy in steering — Shimmy may be A, B, C, D Check for shimmy in steering — Shimmy may be A, B, C, D
caused by unbalanced or out-of-round tires, wheels caused by unbalanced or out-of-round tires, wheels
or brake drums, looseness in steering system, or brake drums, looseness in steering system,
unequal front tire pressure (especially with radial unequal front tire pressure (especially with radial
tires). tires).
Check operation of power steering pump for lack of, A, B, C, D Check operation of power steering pump for lack of, A, B, C, D
or erratic, power assist. or erratic, power assist.
BRAKES: BRAKES:
Check for unusual noise during brake operation. A, B, C, D Check for unusual noise during brake operation. A, B, C, D
Squeal may be caused by glazed lining or lining Squeal may be caused by glazed lining or lining
which is worn to rivets. which is worn to rivets.
Chatter may be caused by worn parts. Chatter may be caused by worn parts.
Check for pull. A, B, C, D Check for pull. A, B, C, D

Pull may be caused by grease on the linings, Pull may be caused by grease on the linings,
worn brake linings and brake drums, worn brake linings and brake drums,
misadjustment or malfunctioning self-adjusters. misadjustment or malfunctioning self-adjusters.
Check for drag. A, B, C, D Check for drag. A, B, C, D

Drag may be caused by misadjustment, broken Drag may be caused by misadjustment, broken
return springs, loose wheel bearings or by return springs, loose wheel bearings or by
malfunctioning brake camshafts. malfunctioning brake camshafts.
33 33
ROAD TEST ROAD TEST
PARKING BRAKES: Inspection PARKING BRAKES: Inspection

Schedule Schedule
Check application and holding ability of spring A, B, C, D Check application and holding ability of spring A, B, C, D
brakes. Make sure the warning light indicates spring brakes. Make sure the warning light indicates spring
brake application. Release and reapply the spring brake application. Release and reapply the spring
brakes. brakes.
HEATER/DEFROSTER: HEATER/DEFROSTER:
Check operation: A, B, C, D Check operation: A, B, C, D

Proper fan speed control. Proper fan speed control.
No excessive noises. No excessive noises.
Proper temperature output. Proper temperature output.
AIR CONDITIONER: AIR CONDITIONER:
Check operation. A, B, C, D Check operation. A, B, C, D

Proper fan speed control. Proper fan speed control.
No excessive noises. No excessive noises.
Proper temperature output. Proper temperature output.
TRANSMISSION/AUX TRANS./TRANSFER CASE/FLYWHEEL PTO: TRANSMISSION/AUX TRANS./TRANSFER CASE/FLYWHEEL PTO:
Shifting should take place quickly and quietly. If A, B, C, D Shifting should take place quickly and quietly. If A, B, C, D
hang-up or clashing occurs, repair or adjustment is hang-up or clashing occurs, repair or adjustment is
Check lever operation noting any difficult movement A, B, C, D Check lever operation noting any difficult movement A, B, C, D
or binding which would indicate the need to check or binding which would indicate the need to check
the linkage. Check for indications of restricted the linkage. Check for indications of restricted
motion in the linkage which could result in partial motion in the linkage which could result in partial
gear engagement and transmission damage. gear engagement and transmission damage.
Check for bearing and gear noises, or excessive A, B, C, D Check for bearing and gear noises, or excessive A, B, C, D
vibration at various road speeds. vibration at various road speeds.
34 34
ROAD TEST ROAD TEST
CARRIER: Inspection CARRIER: Inspection

Schedule Schedule
Check for noise or vibration under drive and coast A, B, C, D Check for noise or vibration under drive and coast A, B, C, D
conditions. conditions.
PROPELLER SHAFT: PROPELLER SHAFT:
Check for noise or vibration at various road speeds. A, B, C, D Check for noise or vibration at various road speeds. A, B, C, D
ENGINE BRAKE: ENGINE BRAKE:
Turn the engine brake switch on. Marked A, B, C, D Turn the engine brake switch on. Marked A, B, C, D
deceleration should be noted when the foot is deceleration should be noted when the foot is
removed from the accelerator pedal. removed from the accelerator pedal.
Testing the engine brake when the vehicle is Testing the engine brake when the vehicle is
lightly loaded, particularly when operating on wet lightly loaded, particularly when operating on wet
or slippery roads, requires extreme caution. Using or slippery roads, requires extreme caution. Using
an engine brake under these conditions may an engine brake under these conditions may
cause the vehicle to skid. cause the vehicle to skid.
35 35
CHASSIS INSPECTION CHASSIS INSPECTION

CAB: Inspection CAB: Inspection
Schedule Schedule
Inspect condition of mirrors and cab glass. A, B, C, D Inspect condition of mirrors and cab glass. A, B, C, D
Check operation of horns (air and electric). A, B, C, D Check operation of horns (air and electric). A, B, C, D
Clean the floor mats and clean any debris from A, B, C, D Clean the floor mats and clean any debris from A, B, C, D
around the treadle valve. around the treadle valve.
Observe operation of windshield wipers, making A, B, C, D Observe operation of windshield wipers, making A, B, C, D
sure they operate in each speed. Check condition sure they operate in each speed. Check condition
and travel of blades. and travel of blades.
Check operation of windshield washers. Make sure A, B, C, D Check operation of windshield washers. Make sure A, B, C, D
the washer reservoir is filled with fluid. the washer reservoir is filled with fluid.
Check operation and condition of back-up lights, tail A, B, C, D Check operation and condition of back-up lights, tail A, B, C, D
lights, brake lights, turn signals, hazard warning lights, brake lights, turn signals, hazard warning
flasher, marker lights, headlights (adjust high and flasher, marker lights, headlights (adjust high and
low beams, if necessary) and instrument panel low beams, if necessary) and instrument panel
lights. lights.
Lubricate the treadle valve and make sure it is B, C, D Lubricate the treadle valve and make sure it is B, C, D
securely mounted. securely mounted.
Check the engine cover for cracks or broken-out B, C, D Check the engine cover for cracks or broken-out B, C, D
sections. Noise Emission Control Maintenance. sections. Noise Emission Control Maintenance.
Check condition and operation of seats and C, D Check condition and operation of seats and C, D
seatbelts, doors and latches, hood and latches. seatbelts, doors and latches, hood and latches.
36 36

Check condition of steel/fiberglass body panels, C, D Check condition of steel/fiberglass body panels, C, D
bumpers and steps. Check torque of chassis fairing bumpers and steps. Check torque of chassis fairing
fasteners. Two different types of M8 x 1.25 fasteners. Two different types of M8 x 1.25
fasteners are used on the fairings, torque values fasteners are used on the fairings, torque values
are as follows: are as follows:
앫 Pan head Torx drive, M8 x 1.25 — 5.4 N•m 앫 Pan head Torx drive, M8 x 1.25 — 5.4 N•m
(48 lb-in) (48 lb-in)
앫 Flanged hex head capscrew, M8 x 1.25 — 앫 Flanged hex head capscrew, M8 x 1.25 —
10.9 N•m (96 lb-in) 10.9 N•m (96 lb-in)
The above torque values are for applications where The above torque values are for applications where
the head of the fastener contacts the fiberglass the head of the fastener contacts the fiberglass
fairing. The M8 x 1.25 Torx drive pan head screw fairing. The M8 x 1.25 Torx drive pan head screw
is also used in certain locations where the head of is also used in certain locations where the head of
the screw contacts a metal bracket. In those the screw contacts a metal bracket. In those
applications, the pan head screw is tightened to applications, the pan head screw is tightened to
25.8 N•m (19 lb-ft). 25.8 N•m (19 lb-ft).
Check the condition of the cab mounting. Inspect C, D Check the condition of the cab mounting. Inspect C, D
and adjust cab rear mounting (air-suspended cabs) and adjust cab rear mounting (air-suspended cabs)
as required. On LE and MR models, check the as required. On LE and MR models, check the
anti-vibration pads on the cab mount V-brackets for anti-vibration pads on the cab mount V-brackets for
wear. Replace any pads that are worn or missing. wear. Replace any pads that are worn or missing.
Also check alignment of the cab mount V-blocks Also check alignment of the cab mount V-blocks
and adjust as required. (Refer to “CAB MOUNT and adjust as required. (Refer to “CAB MOUNT
MAINTENANCE — LEU AND MRU MODELS” on MAINTENANCE — LEU AND MRU MODELS” on
page 240.) page 240.)
Check the condition of the sound-absorbing C, D Check the condition of the sound-absorbing C, D
material that is affixed to the hood and/or cab. material that is affixed to the hood and/or cab.
Check for tears and for suitable attachment. Check for tears and for suitable attachment.
Excessive dirt can be removed with a mild soap and Excessive dirt can be removed with a mild soap and
water solution. Noise Emission Control water solution. Noise Emission Control
Maintenance. Maintenance.
37 37

Check the splash shields that are located inside the C, D Check the splash shields that are located inside the C, D
wheel housings. Look for tears or broken-out wheel housings. Look for tears or broken-out
sections. Noise Emission Control Maintenance. sections. Noise Emission Control Maintenance.
Check operation of window regulators. C, D Check operation of window regulators. C, D
V-MAC: V-MAC:
Check for any faults which may be logged into the A, B, C, D Check for any faults which may be logged into the A, B, C, D
V-MAC system. Refer to the applicable V-MAC V-MAC system. Refer to the applicable V-MAC
Operator’s Manual or the V-MAC Service Manual Operator’s Manual or the V-MAC Service Manual
for complete troubleshooting procedures and fault for complete troubleshooting procedures and fault
diagnosis. diagnosis.
TILT CAB: TILT CAB:
Check cab tilt pump reservoir fluid level. Add fluid, if B, C, D Check cab tilt pump reservoir fluid level. Add fluid, if B, C, D
necessary. (See “LUBRICANT SPECIFICATIONS” necessary. (See “LUBRICANT SPECIFICATIONS”
on page 267.) on page 267.)
Check operation and condition of tilt mechanism, B, C, D Check operation and condition of tilt mechanism, B, C, D
latches, safety prop, hinges and brackets. latches, safety prop, hinges and brackets.
Check anti-vibration pads on frame-mounted C, D Check anti-vibration pads on frame-mounted C, D

V-brackets and replace if missing or damaged. V-brackets and replace if missing or damaged.
Check and adjust (as required) cab rear mounting C, D Check and adjust (as required) cab rear mounting C, D
alignment. alignment.
38 38
BATTERY: Inspection BATTERY: Inspection

Schedule Schedule
If equipped with low maintenance-type battery with A, B, C, D If equipped with low maintenance-type battery with A, B, C, D
removable plastic caps, check that the electrolyte removable plastic caps, check that the electrolyte
level is a minimum of 9.5 mm (3/8 inch) above level is a minimum of 9.5 mm (3/8 inch) above
plates. Add distilled or good drinking water (no plates. Add distilled or good drinking water (no
mineral water), if necessary. On maintenance-free mineral water), if necessary. On maintenance-free
batteries with flush-type cover, check batteries with flush-type cover, check
state-of-charge indicator. state-of-charge indicator.
Clean battery terminals with solution of baking soda B, C, D Clean battery terminals with solution of baking soda B, C, D
or household ammonia. Flush with clear water and or household ammonia. Flush with clear water and
dry. Tighten terminals. Coat terminals with light film dry. Tighten terminals. Coat terminals with light film
of non-metallic grease. of non-metallic grease.
Check condition and routing of the battery cables. B, C, D Check condition and routing of the battery cables. B, C, D
Make sure there is no possibility of chafing and/or Make sure there is no possibility of chafing and/or
shorting. shorting.
For low maintenance-type batteries, test the C, D For low maintenance-type batteries, test the C, D
electrolyte with a hydrometer: 1.250–1.280 battery electrolyte with a hydrometer: 1.250–1.280 battery
OK — less than 1.250, remove battery and OK — less than 1.250, remove battery and
recharge. Check with high discharge rate cell tester. recharge. Check with high discharge rate cell tester.
Remove batteries. Clean top and case. Make sure C, D Remove batteries. Clean top and case. Make sure C, D
case is not cracked. Clean, paint and tighten battery case is not cracked. Clean, paint and tighten battery
hold-down arrangement. hold-down arrangement.
39 39
STARTER: Inspection STARTER: Inspection

Schedule Schedule
Check tightness of the starter mounting bolts and C, D Check tightness of the starter mounting bolts and C, D
the nuts that secure the cables to both the starter the nuts that secure the cables to both the starter
solenoid and the starter motor. Torque solenoid and the starter motor. Torque
specifications are as follows: specifications are as follows:
앫 Starter mounting bolts — 260 N•m (192 lb-ft) 앫 Starter mounting bolts — 260 N•m (192 lb-ft)
앫 Starter cable nut (1/2 x 13) — 26 N•m 앫 Starter cable nut (1/2 x 13) — 26 N•m
(270 lb-in) (270 lb-in)
앫 Starter relay nuts (#10-32) — 2.6 N•m 앫 Starter relay nuts (#10-32) — 2.6 N•m
(23 lb-in) (23 lb-in)
Disconnect the batteries by disconnecting the Disconnect the batteries by disconnecting the
negative battery first, then the positive cable before negative battery first, then the positive cable before
checking the tightness of the starter and starter checking the tightness of the starter and starter
solenoid cable nuts. solenoid cable nuts.
AIR STARTER: AIR STARTER:

Clean the strainer which is in line to the control C, D Clean the strainer which is in line to the control C, D
valve. valve.
Check air starting system for leakage (should not C, D Check air starting system for leakage (should not C, D
exceed 14 kPa [2 psi] per hour from 897 kPa exceed 14 kPa [2 psi] per hour from 897 kPa
[130 psi]). [130 psi]).
Remove safety valve and test; should open at C, D Remove safety valve and test; should open at C, D
1034 kPa (150 psi). Check pressure regulator; 1034 kPa (150 psi). Check pressure regulator;
should open at 655 kPa (95 psi). should open at 655 kPa (95 psi).
Check operation of control valve. Check operation C, D Check operation of control valve. Check operation C, D
of check valve by reducing main air reservoir of check valve by reducing main air reservoir
pressure. pressure.
Check air starter reservoir mounting. C, D Check air starter reservoir mounting. C, D
40 40
AIR SYSTEM: Inspection AIR SYSTEM: Inspection

Schedule Schedule
Inspect the air system for leaks by fully pressurizing A, B, C, D Inspect the air system for leaks by fully pressurizing A, B, C, D
the system, releasing the parking brakes and the system, releasing the parking brakes and
observing any pressure drop as indicated by the observing any pressure drop as indicated by the
dashboard air pressure gauge. Pressure drop dashboard air pressure gauge. Pressure drop
should be less than 2 psi per minute for a truck, or should be less than 2 psi per minute for a truck, or
less than 3 psi per minute for a tractor and trailer less than 3 psi per minute for a tractor and trailer
combination. Make a full treadle application and combination. Make a full treadle application and
again check for leaks by observing the air pressure again check for leaks by observing the air pressure
gauge. Pressure drop should not exceed 3 psi per gauge. Pressure drop should not exceed 3 psi per
minute for a truck, or 4 psi per minute for a tractor minute for a truck, or 4 psi per minute for a tractor
and trailer combination. and trailer combination.
With air reservoirs fully charged, drain reservoirs A, B, C, D With air reservoirs fully charged, drain reservoirs A, B, C, D
slowly and completely. Spring brakes should apply slowly and completely. Spring brakes should apply
automatically when air pressure decreases to automatically when air pressure decreases to
276 kPa (40 psi). 276 kPa (40 psi).
Check alcohol evaporator reservoir level (if so A, B, C, D Check alcohol evaporator reservoir level (if so A, B, C, D
equipped). Add fluid, if necessary. (Use only equipped). Add fluid, if necessary. (Use only
188 proof methanol alcohol.) Check that the 188 proof methanol alcohol.) Check that the
connections are tight. connections are tight.
Check air dryer for proper operation. Consult the air B, C, D Check air dryer for proper operation. Consult the air B, C, D
dryer manufacturer’s service literature for dryer manufacturer’s service literature for
recommended service intervals and procedures. recommended service intervals and procedures.
Check the condition of all brake hoses. Check for B, C, D Check the condition of all brake hoses. Check for B, C, D
interference and/or chafing. interference and/or chafing.
Check mounting of air reservoirs. C, D Check mounting of air reservoirs. C, D
Perform dual circuit brake test. (Refer to “Dual C, D Perform dual circuit brake test. (Refer to “Dual C, D
Circuit Brake System Function Test” on page 232.) Circuit Brake System Function Test” on page 232.)
41 41
Service air system components: Service air system components:
To prevent possible injury, chock wheels and drain To prevent possible injury, chock wheels and drain
air brake system completely before performing air brake system completely before performing
any maintenance on air brake system any maintenance on air brake system
Inspection Inspection
Governor Schedule Governor Schedule
Check governor cut-in/cutout operation and test for A, B, C, D Check governor cut-in/cutout operation and test for A, B, C, D
excessive leakage. Replace, if necessary. excessive leakage. Replace, if necessary.
Low Pressure Indicator Low Pressure Indicator

Double Check Valve and Stoplamp Switch Double Check Valve and Stoplamp Switch
Check lamps and electrical connections. B, C, D Check lamps and electrical connections. B, C, D
Check operation and test for excessive leakage. B, C, D Check operation and test for excessive leakage. B, C, D
Replace if necessary. Replace if necessary.
Trailer Supply Valve Trailer Supply Valve

Tractor Parking Brake Control Valve Tractor Parking Brake Control Valve
Parking Control Valve Parking Control Valve
Trailer Control Valve Trailer Control Valve
Check operation of valves and test for excessive B, C, D Check operation of valves and test for excessive B, C, D
leakage. Replace, if necessary. leakage. Replace, if necessary.
42 42
Check Valve Inspection Check Valve Inspection

Double Check Valve Schedule Double Check Valve Schedule
Treadle Valve Treadle Valve

Quick Release Valve Quick Release Valve
Ratio Valve Ratio Valve
Pressure Protection Valve Pressure Protection Valve
Tractor Protection Valve Tractor Protection Valve
Spring Brake Control Valve Spring Brake Control Valve
Relay Valve Relay Valve
COOLING SYSTEM: COOLING SYSTEM:
Check the cooling system for leaks. A, B, C, D Check the cooling system for leaks. A, B, C, D
Check the coolant level in the radiator, recovery A, B, C, D Check the coolant level in the radiator, recovery A, B, C, D
tank or surge tank. Refer to “COOLING SYSTEM” tank or surge tank. Refer to “COOLING SYSTEM”
on page 91 for information. Add coolant, if on page 91 for information. Add coolant, if
necessary. Mack Trucks, Inc. recommends a necessary. Mack Trucks, Inc. recommends a
coolant mixture between 40% – 60% of coolant mixture between 40% – 60% of
antifreeze/quality water. Do not exceed a 60% antifreeze/quality water. Do not exceed a 60%
concentration of antifreeze. concentration of antifreeze.
At each oil and filter change interval, test the At each oil and filter change interval, test the
coolant and add supplemental coolant additive coolant and add supplemental coolant additive
(SCA) packets or change the coolant conditioner as (SCA) packets or change the coolant conditioner as
required. Refer to “Coolant Conditioning” on page required. Refer to “Coolant Conditioning” on page
100 for detailed information. 100 for detailed information.
43 43
COOLING SYSTEM: Inspection COOLING SYSTEM: Inspection

Check inside the radiator for corrosion. (See A, B, C, D Check inside the radiator for corrosion. (See A, B, C, D
“Cooling System Corrosion” on page 103.) “Cooling System Corrosion” on page 103.)
Check and record degree of antifreeze protection. C, D Check and record degree of antifreeze protection. C, D
Add antifreeze to obtain required protection level for Add antifreeze to obtain required protection level for
anticipated ambient temperatures. anticipated ambient temperatures.
Check condition of hoses and clamps. Check for A, B, C, D Check condition of hoses and clamps. Check for A, B, C, D
leaks and tighten all hose clamps. Gaseous leaks and tighten all hose clamps. Gaseous
Inspect radiator cap gasket. Pressure-test cap. C, D Inspect radiator cap gasket. Pressure-test cap. C, D
MACK MP engines use a 16-lb. pressure cap. MACK MP engines use a 16-lb. pressure cap.
Using compressed air delivered from the rear of the C, D Using compressed air delivered from the rear of the C, D
radiator, clean the core fins and tubes. Gaseous radiator, clean the core fins and tubes. Gaseous
Clean any debris that may have accumulated C, D Clean any debris that may have accumulated C, D
between the radiator core, charge air cooler core between the radiator core, charge air cooler core
and the air conditioner condenser core. and the air conditioner condenser core.
Check condition and security of the radiator C, D Check condition and security of the radiator C, D
mounts. mounts.
Inspect the cooling fan shroud for tears or C, D Inspect the cooling fan shroud for tears or C, D
broken-out sections. Also check for proper broken-out sections. Also check for proper
alignment between the fan and the shroud. Noise alignment between the fan and the shroud. Noise
Inspect the electronically controlled viscous fan C, D Inspect the electronically controlled viscous fan C, D
drive for leakage, and make sure it is securely drive for leakage, and make sure it is securely
mounted. With the engine stopped (cold engine) mounted. With the engine stopped (cold engine)
turn the fan by hand to ensure the drive is not turn the fan by hand to ensure the drive is not
seized. Inspect the air-controlled fan clutch (if so seized. Inspect the air-controlled fan clutch (if so
equipped) for proper operation. Check the fan for equipped) for proper operation. Check the fan for
bent, cracked or broken blades and replace as bent, cracked or broken blades and replace as
necessary. Noise Emission Control necessary. Noise Emission Control
44 44
ALTERNATOR: Inspection ALTERNATOR: Inspection

Schedule Schedule
Make sure alternator is securely mounted. Tighten B, C, D Make sure alternator is securely mounted. Tighten B, C, D
the alternator mounting hardware to the following the alternator mounting hardware to the following
specifications: specifications:
앫 Alternator top mounting bolt — 81–95 N•m 앫 Alternator top mounting bolt — 81–95 N•m
(60–70 lb-ft) (60–70 lb-ft)
앫 Alternator adjusting link bolt — 81–95 N•m 앫 Alternator adjusting link bolt — 81–95 N•m
(60–70 lb-ft) (60–70 lb-ft)
앫 Alternator lower mounting bolt — 81–95 N•m 앫 Alternator lower mounting bolt — 81–95 N•m
(60–70 lb-ft) (60–70 lb-ft)
앫 Alternator mounting bracket-to-block — 앫 Alternator mounting bracket-to-block —
82–92 N•m (61–68 lb-ft) 82–92 N•m (61–68 lb-ft)
Inspect alternator connections. C, D Inspect alternator connections. C, D
EXTERNAL REGULATOR: EXTERNAL REGULATOR:
Check mounting and connections. C, D Check mounting and connections. C, D
45 45
BELTS: Inspection BELTS: Inspection

Schedule Schedule
Check condition of all drive belts. Replace any A, B, C, D Check condition of all drive belts. Replace any A, B, C, D
frayed, cracked, worn or oil-soaked belts. frayed, cracked, worn or oil-soaked belts.
If the engine is not equipped with an automatic A, B, C, D If the engine is not equipped with an automatic A, B, C, D
tensioner, use a tension gauge to check and adjust tensioner, use a tension gauge to check and adjust
belt tension. belt tension.
On engines equipped with an automatic belt On engines equipped with an automatic belt
tensioner, belt tension cannot be checked. If the tensioner, belt tension cannot be checked. If the
belt is loose, check the condition of the automatic belt is loose, check the condition of the automatic
belt tensioner and replace as necessary. belt tensioner and replace as necessary.
Using a straight edge, check the alignment of all B, C, D Using a straight edge, check the alignment of all B, C, D
belt pulleys. belt pulleys.
Check condition of the automatic belt tensioner. D Check condition of the automatic belt tensioner. D
(Refer to “Automatic Belt Tensioner Maintenance” (Refer to “Automatic Belt Tensioner Maintenance”
on page 87.) on page 87.)
46 46

Schedule Schedule
Check engine oil level. Add oil, if necessary. (See A, B, C, D Check engine oil level. Add oil, if necessary. (See A, B, C, D
“LUBRICANT SPECIFICATIONS” on page 267.) “LUBRICANT SPECIFICATIONS” on page 267.)
Inspect engine for any leakage of fuel, oil, coolant, A, B, C, D Inspect engine for any leakage of fuel, oil, coolant, A, B, C, D
air or exhaust. Correct as required. air or exhaust. Correct as required.
Information outlining fuel injection nozzle Information outlining fuel injection nozzle
maintenance, fuel filter changes and engine oil and maintenance, fuel filter changes and engine oil and
oil filter changes is given in the SPECIFIC oil filter changes is given in the SPECIFIC
MAINTENANCE section of this manual. MAINTENANCE section of this manual.
EGR System A, B, C, D EGR System A, B, C, D

앫 Wire Harnesses/Connectors — Inspect 앫 Wire Harnesses/Connectors — Inspect
protective coatings on wire harnesses and protective coatings on wire harnesses and
connectors, especially heat resistant connectors, especially heat resistant
coverings (reflective and/or insulated). Make coverings (reflective and/or insulated). Make
sure all protective coverings are returned to sure all protective coverings are returned to
their original positions if disturbed. Repair or their original positions if disturbed. Repair or
replace defective parts as required. Gaseous replace defective parts as required. Gaseous
앫 EGR Tubes and Hoses — Inspect connecting 앫 EGR Tubes and Hoses — Inspect connecting
tubes and hoses for signs of leakage or tubes and hoses for signs of leakage or
chafing. Replace and/or repair defective parts chafing. Replace and/or repair defective parts
as required. Gaseous Emission Control as required. Gaseous Emission Control
Check viscous-type vibration dampers for dents and C, D Check viscous-type vibration dampers for dents and C, D
leakage. leakage.
Inspect front and rear engine mount insulators for C, D Inspect front and rear engine mount insulators for C, D
deterioration. If metal members come in contact, deterioration. If metal members come in contact,
replace insulator. replace insulator.
47 47
AIR CLEANER: Inspection AIR CLEANER: Inspection

Schedule Schedule
Replace the element with a MACK-approved A, B, C, D Replace the element with a MACK-approved A, B, C, D
element according to MACK recommendations element according to MACK recommendations
when the indicator locks in the red zone, or the when the indicator locks in the red zone, or the
gauge indicates 20 or 25 inches of water for gauge indicates 20 or 25 inches of water for
applicable engine. Refer to “AIR CLEANER applicable engine. Refer to “AIR CLEANER
MAINTENANCE” on page 113 for a listing of inlet MAINTENANCE” on page 113 for a listing of inlet
restriction per engine model. Reset indicator after restriction per engine model. Reset indicator after
element change. The air filter element should be element change. The air filter element should be
replaced yearly, even if maximum restriction has not replaced yearly, even if maximum restriction has not
been reached. Gaseous Emission Control been reached. Gaseous Emission Control
ENGINE AIR INDUCTION SYSTEM: ENGINE AIR INDUCTION SYSTEM:
Inspect condition of all hoses, pipes, ducts, tubing, A, B, C, D Inspect condition of all hoses, pipes, ducts, tubing, A, B, C, D
elbow connections and inline intake silencers. elbow connections and inline intake silencers.
Check for alignment, leakage, engagement and Check for alignment, leakage, engagement and
possible interference. Replace any items having possible interference. Replace any items having
cracks or holes. Noise & Gaseous Emission cracks or holes. Noise & Gaseous Emission
Control Maintenance. Control Maintenance.
Inspect all clamps, brackets and fasteners. Torque A, B, C, D Inspect all clamps, brackets and fasteners. Torque A, B, C, D
all hose clamps. (See “HOSE CLAMP TORQUES” all hose clamps. (See “HOSE CLAMP TORQUES”
on page 110.) Noise Emission Control on page 110.) Noise Emission Control
Check all turbocharger connections for tightness A, B, C, D Check all turbocharger connections for tightness A, B, C, D
and leaks. Repair as necessary. and leaks. Repair as necessary.
Additional turbocharger maintenance procedures Additional turbocharger maintenance procedures

are given under “TURBOCHARGERS” on page are given under “TURBOCHARGERS” on page
117. 117.
48 48
CHASSIS-MOUNTED CHARGE AIR COOLERS: Inspection CHASSIS-MOUNTED CHARGE AIR COOLERS: Inspection
Schedule Schedule
Check all air ducts and gasket connections. Torque A, B, C, D Check all air ducts and gasket connections. Torque A, B, C, D
hose clamps to specifications. Refer to “HOSE hose clamps to specifications. Refer to “HOSE
CLAMP TORQUES” on page 110. Gaseous CLAMP TORQUES” on page 110. Gaseous
Check charge air cooler core fins for external C, D Check charge air cooler core fins for external C, D
damage, debris or salt corrosion. Use a firm bristle damage, debris or salt corrosion. Use a firm bristle
brush to remove corrosion, and compressed air to brush to remove corrosion, and compressed air to
clean debris from the core. Gaseous Emission clean debris from the core. Gaseous Emission
Check for cracks in the welds that join the side C, D Check for cracks in the welds that join the side C, D
tanks to the core, and check the mounting brackets tanks to the core, and check the mounting brackets
for security and condition. Torque mounts to 41 N•m for security and condition. Torque mounts to 41 N•m
(30 lb-ft). Gaseous Emission Control (30 lb-ft). Gaseous Emission Control
FUEL SYSTEM: FUEL SYSTEM:
Check nozzle lines for leaks and clamps for C, D Check nozzle lines for leaks and clamps for C, D
tightness. Be sure lines do not rub. tightness. Be sure lines do not rub.
49 49
FUEL TANKS: Inspection FUEL TANKS: Inspection

Schedule Schedule
Check filler cap and gasket for proper sealing. B, C, D Check filler cap and gasket for proper sealing. B, C, D
Check for plugged or obstructed fuel tank vents. C, D Check for plugged or obstructed fuel tank vents. C, D
Inspect the fuel tank mounting and fuel line clamps. C, D Inspect the fuel tank mounting and fuel line clamps. C, D
The fuel tank caps on some MACK diesel powered The fuel tank caps on some MACK diesel powered
chassis are vented. Should the cap be lost or chassis are vented. Should the cap be lost or
damaged in any way, it must be replaced with a MACK damaged in any way, it must be replaced with a MACK
approved vented cap only. Using any other type of cap approved vented cap only. Using any other type of cap
may result in fuel tank damage and/or poor engine may result in fuel tank damage and/or poor engine
performance. performance.
Certain other MACK chassis have vented fuel tanks Certain other MACK chassis have vented fuel tanks
and do not use vented fuel tank caps. and do not use vented fuel tank caps.
Do not fill the fuel tanks to more than 95% of liquid Do not fill the fuel tanks to more than 95% of liquid
capacity. capacity.
50 50
DIESEL PARTICULATE FILTER/EXHAUST Inspection DIESEL PARTICULATE FILTER/EXHAUST Inspection

SYSTEM: Schedule SYSTEM: Schedule
Inspect the exhaust system for leaks at the seams, A, B, C, D Inspect the exhaust system for leaks at the seams, A, B, C, D
and the inlet and outlet connections. Also check for and the inlet and outlet connections. Also check for
holes in the muffler body. Replace as necessary. holes in the muffler body. Replace as necessary.
Noise Emission Control Maintenance. Noise Emission Control Maintenance.
Inspect the exhaust system tubing for holes, A, B, C, D Inspect the exhaust system tubing for holes, A, B, C, D
including all flexible pipes, and check for exhaust gas including all flexible pipes, and check for exhaust gas
leakage at all connections. Replace as necessary. leakage at all connections. Replace as necessary.
Check for gasket leakage at the exhaust manifold A, B, C, D Check for gasket leakage at the exhaust manifold A, B, C, D
and at the turbocharger connections. Noise and at the turbocharger connections. Noise
Inspect the condition of all exhaust system clamps. B, C, D Inspect the condition of all exhaust system clamps. B, C, D
Tighten or replace as required. Noise Emission Tighten or replace as required. Noise Emission
51 51
DIESEL PARTICULATE FILTER/EXHAUST DIESEL PARTICULATE FILTER/EXHAUST

SYSTEM: Inspection SYSTEM: Inspection
Check the condition of all exhaust system supports B, C, D Check the condition of all exhaust system supports B, C, D
and brackets. Repair or replace as necessary. and brackets. Repair or replace as necessary.
The ash cleaning interval for both catalyzed and The ash cleaning interval for both catalyzed and
non-catalyzed DPF systems is 400 000 km/ non-catalyzed DPF systems is 400 000 km/
250,000 miles or 4,500 hours, whichever occurs first. 250,000 miles or 4,500 hours, whichever occurs first.
For catalyzed DPF systems, the aftertreatment For catalyzed DPF systems, the aftertreatment
hydrocarbon injector (AHI) must be cleaned at each hydrocarbon injector (AHI) must be cleaned at each
240 000 km/150,000 mile or 4,500 hour interval, 240 000 km/150,000 mile or 4,500 hour interval,
For the non-catalyzed DPF system, clean the For the non-catalyzed DPF system, clean the
ignition electrodes and the injection nozzle at each ignition electrodes and the injection nozzle at each
161 000 km/100,000 mile or 2,400 hour interval, 161 000 km/100,000 mile or 2,400 hour interval,
52 52
CLUTCH: Inspection CLUTCH: Inspection

Schedule Schedule
Inspect linkage for wear. C, D Inspect linkage for wear. C, D
Check clutch pedal free travel. DO NOT allow less C, D Check clutch pedal free travel. DO NOT allow less C, D
than 12.7 mm (1/2 inch) of free travel. If not within than 12.7 mm (1/2 inch) of free travel. If not within
specifications, adjust as necessary. (See “CLUTCH specifications, adjust as necessary. (See “CLUTCH
ADJUSTMENT” on page 247.) ADJUSTMENT” on page 247.)
STEERING GEAR: STEERING GEAR:
Perform a static shake test to check for wear and/or A, B, C, D Perform a static shake test to check for wear and/or A, B, C, D
looseness in the steering linkage (steering shaft looseness in the steering linkage (steering shaft
U-joints and yokes, drag link ends and cross steer U-joints and yokes, drag link ends and cross steer
tube ends). Refer to “FRONT AXLE STATIC SHAKE tube ends). Refer to “FRONT AXLE STATIC SHAKE
TEST” on page 182. TEST” on page 182.
Inspect the condition of the steering gear mounting A, B, C, D Inspect the condition of the steering gear mounting A, B, C, D
brackets, and check the tightness of all the brackets, and check the tightness of all the
fasteners. Inspect the steering gear for leaks. fasteners. Inspect the steering gear for leaks.
Check the torque of the steering shaft pinch bolts. C, D Check the torque of the steering shaft pinch bolts. C, D
Replace any corroded pinch bolts or nuts. Replace any corroded pinch bolts or nuts.
POWER STEERING: POWER STEERING:
Check for leakage in the hoses, pump, steering A, B, C, D Check for leakage in the hoses, pump, steering A, B, C, D
gear and reservoir. gear and reservoir.
Check fluid level in reservoir and add fluid, if A, B, C, D Check fluid level in reservoir and add fluid, if A, B, C, D
Check relief stop settings. C, D Check relief stop settings. C, D
Change power steering fluid and filter. Refer to D Change power steering fluid and filter. Refer to D
“Power Steering Fluid Change” on page 155 for “Power Steering Fluid Change” on page 155 for
more information. more information.
53 53
Axle Alignment: Axle Alignment:
For information concerning factors that influence tire For information concerning factors that influence tire
wear, tire rotation, driving habits, tire loading, tire wear, tire rotation, driving habits, tire loading, tire
inspection, tire selection and inflation pressures, refer inspection, tire selection and inflation pressures, refer
to “Factors That Influence Tire Wear” on page 224. to “Factors That Influence Tire Wear” on page 224.
At the first A inspection interval, front and rear axle At the first A inspection interval, front and rear axle
alignment must be checked and adjusted if out of alignment must be checked and adjusted if out of
specification. Thereafter, front axle alignment should specification. Thereafter, front axle alignment should
be checked and adjusted at each C and D interval, be checked and adjusted at each C and D interval,
and rear axle alignment should be checked and and rear axle alignment should be checked and
adjusted at each D interval. adjusted at each D interval.
STEERING AXLE ALIGNMENT: Inspection STEERING AXLE ALIGNMENT: Inspection

Schedule Schedule
Under normal use, toe may change and occasional C, D Under normal use, toe may change and occasional C, D
adjustment is recommended to optimize tire wear adjustment is recommended to optimize tire wear
and handling. Check toe and adjust if out of and handling. Check toe and adjust if out of
specification. If driver reports indicate need, or specification. If driver reports indicate need, or
irregular tire wear is present, check caster and irregular tire wear is present, check caster and
adjust if out of specification. adjust if out of specification.
54 54
REAR AXLE(S) ALIGNMENT: Inspection REAR AXLE(S) ALIGNMENT: Inspection

Schedule Schedule
If the vehicle is equipped with one of the following D If the vehicle is equipped with one of the following D
adjustable rear suspensions, MACK AL, AL II, adjustable rear suspensions, MACK AL, AL II,
MaxAir™ 40/40A, MaxLite™ 20–40, MaxLite™ MaxAir™ 40/40A, MaxLite™ 20–40, MaxLite™
20–40 EZ, ST, Chalmers, Hendrickson Bar Pin, 20–40 EZ, ST, Chalmers, Hendrickson Bar Pin,
Neway or Reyco, check axle alignment and adjust Neway or Reyco, check axle alignment and adjust
as required. as required.
If the vehicle is equipped with one of the following If the vehicle is equipped with one of the following
non-adjustable suspensions, MACK SS, SW or non-adjustable suspensions, MACK SS, SW or
Hendrickson straight pin, tires should be monitored for Hendrickson straight pin, tires should be monitored for
signs of irregular wear. Tire rotation is recommended signs of irregular wear. Tire rotation is recommended
to optimize tire life and achieve even wear. The to optimize tire life and achieve even wear. The
suspension should be monitored for signs of suspension should be monitored for signs of
component wear. component wear.
Before checking axle alignment on non-adjustable Before checking axle alignment on non-adjustable
suspensions, a thorough inspection of all components suspensions, a thorough inspection of all components
that require maintenance must be performed. Any that require maintenance must be performed. Any
component in need of replacement or maintenance component in need of replacement or maintenance
must be repaired prior to performing an axle must be repaired prior to performing an axle
alignment. Refer to the Frame, Axle and Suspension alignment. Refer to the Frame, Axle and Suspension
Service and Total Vehicle Alignment, 14-103, for Service and Total Vehicle Alignment, 14-103, for
proper repair/replacement of suspension components. proper repair/replacement of suspension components.
FRONT DRIVE AXLE: FRONT DRIVE AXLE:
Check carrier lube level. Add oil, if necessary. C, D Check carrier lube level. Add oil, if necessary. C, D
55 55
FRONT AXLE AND SUSPENSION: Inspection FRONT AXLE AND SUSPENSION: Inspection
Schedule Schedule
Perform a static shake test to check for broken A, B, C, D Perform a static shake test to check for broken A, B, C, D
spring leaves, particularly in the area of the spring spring leaves, particularly in the area of the spring
leaf wrapper. Refer to “FRONT AXLE STATIC leaf wrapper. Refer to “FRONT AXLE STATIC
SHAKE TEST” on page 182. SHAKE TEST” on page 182.
Check for broken spring leaves. A, B, C, D Check for broken spring leaves. A, B, C, D
Check for wheel seal leaks. A, B, C, D Check for wheel seal leaks. A, B, C, D
Check oil-lubricated wheel bearing lube level. Add A, B, C, D Check oil-lubricated wheel bearing lube level. Add A, B, C, D
oil, if necessary. oil, if necessary.
Chassis with front driving axles may have oil- or Chassis with front driving axles may have oil- or
grease-lubricated front wheel bearings. Consult the grease-lubricated front wheel bearings. Consult the
specific axle manufacturer’s service literature for specific axle manufacturer’s service literature for
service procedures and lubrication service procedures and lubrication
recommendations. recommendations.
Check for wear in the kingpins, bushings and C, D Check for wear in the kingpins, bushings and C, D
bearings by jacking up the front axle and moving bearings by jacking up the front axle and moving
the wheel in and out at the top and bottom. the wheel in and out at the top and bottom.
On MACK FA(W) front axles only, check steering On MACK FA(W) front axles only, check steering
knuckle to front axle beam clearance, and adjust if knuckle to front axle beam clearance, and adjust if
necessary at the first A inspection interval. necessary at the first A inspection interval.
Thereafter, this check must be performed at each C Thereafter, this check must be performed at each C
and D inspection. and D inspection.
Check steering knuckle to front axle beam C, D Check steering knuckle to front axle beam C, D
clearance and adjust, if necessary (MACK FA[W] clearance and adjust, if necessary (MACK FA[W]
front axles only). front axles only).
56 56
Inspect condition of front axle beam and tie rod C, D Inspect condition of front axle beam and tie rod C, D
ends. ends.
Inspect steering knuckles for cracks. Pay particular C, D Inspect steering knuckles for cracks. Pay particular C, D
attention to the areas of the steering lever boss, attention to the areas of the steering lever boss,
cross steering tube boss and the lower king pin cross steering tube boss and the lower king pin
boss. Refer to “STEERING KNUCKLE boss. Refer to “STEERING KNUCKLE
INSPECTION” on page 179 for procedures. INSPECTION” on page 179 for procedures.
Inspect shock absorbers for control, binding or C, D Inspect shock absorbers for control, binding or C, D
leaks; insulators and mountings for wear, leaks; insulators and mountings for wear,
deterioration or breakage. deterioration or breakage.
Check for broken center bolts, shifted axle, loose or C, D Check for broken center bolts, shifted axle, loose or C, D
damaged rebound bumper, spring clips, shackles, damaged rebound bumper, spring clips, shackles,
spring cap or hanger brackets. spring cap or hanger brackets.
Torque spring clips (U-bolts). (See “SPRING CLIP C, D Torque spring clips (U-bolts). (See “SPRING CLIP C, D
(U-BOLT) TORQUE” on page 183.) (U-BOLT) TORQUE” on page 183.)
Remove all wheels. D Remove all wheels. D
Check wheel bearing end play — unitized hubs on D Check wheel bearing end play — unitized hubs on D
MACK FXL axles. MACK FXL axles.
Clean and inspect wheel bearings. D Clean and inspect wheel bearings. D
For chassis equipped with unitized wheel hubs, the For chassis equipped with unitized wheel hubs, the
hubs are sealed and lubricated for life. Do not hubs are sealed and lubricated for life. Do not
disassemble and attempt to repair a unitized wheel disassemble and attempt to repair a unitized wheel
hub. Refer to the specific manufacturer’s service hub. Refer to the specific manufacturer’s service
literature for detailed information. literature for detailed information.
Repack grease-type wheel bearings. D Repack grease-type wheel bearings. D

Inspect condition of brake lining/disc pads. D Inspect condition of brake lining/disc pads. D
Measure and record brake lining thickness. D Measure and record brake lining thickness. D
57 57
Inspect, measure and record drum/rotor wear in D Inspect, measure and record drum/rotor wear in D
mm (inches). Compare measurement with mm (inches). Compare measurement with
dimension cast into the drum/rotor. dimension cast into the drum/rotor.
Inspect brake spiders, mounting bolts and/or disc D Inspect brake spiders, mounting bolts and/or disc D
calipers. calipers.
Inspect brake shoes. D Inspect brake shoes. D
Inspect brake cams and bushings (cam brakes). D Inspect brake cams and bushings (cam brakes). D
Replace wheel bearing lube seals. D Replace wheel bearing lube seals. D
Reinstall wheels and adjust bearings. D Reinstall wheels and adjust bearings. D
Fill oil-type wheel bearings to specified level. (See D Fill oil-type wheel bearings to specified level. (See D
“LUBRICANT SPECIFICATIONS” on page 267.) “LUBRICANT SPECIFICATIONS” on page 267.)
It is extremely important to use a retaining It is extremely important to use a retaining

method when working on all spring brake method when working on all spring brake
chambers. The spring is under heavy chambers. The spring is under heavy
compression and can expand rapidly with great compression and can expand rapidly with great
force and cause injury. force and cause injury.
Check brake air chambers for leakage. Make A, B, C, D Check brake air chambers for leakage. Make A, B, C, D
several brake applications and observe that push several brake applications and observe that push
rods respond quickly and with no indications of rods respond quickly and with no indications of
binding. Refer to the Air and Brake System Service binding. Refer to the Air and Brake System Service
Manual, 16-104, for more detailed maintenance Manual, 16-104, for more detailed maintenance
information. information.
Measure push rod travel. Stroke should be as short A, B, C, D Measure push rod travel. Stroke should be as short A, B, C, D
as possible without allowing the brakes to drag. as possible without allowing the brakes to drag.
Adjust manual slack adjusters as necessary. Adjust manual slack adjusters as necessary.
Automatic slack adjusters should not require Automatic slack adjusters should not require
periodic adjustments. Refer to the Air and Brake periodic adjustments. Refer to the Air and Brake
System Service Manual, 16-104, for more detailed System Service Manual, 16-104, for more detailed
58 58
TRANSMISSION/AUX. TRANS. TRANSFER Inspection TRANSMISSION/AUX. TRANS. TRANSFER Inspection

CASE/FLYWHEEL PTO: Schedule CASE/FLYWHEEL PTO: Schedule
Inspect for leaks at seals, covers and plugs. A, B, C, D Inspect for leaks at seals, covers and plugs. A, B, C, D
Check lube level. Add oil, if necessary. (See table on A, B, C, D Check lube level. Add oil, if necessary. (See table on A, B, C, D
page 268 for recommended lubricants and page 268 for recommended lubricants and
capacities. For lubricant change procedures, refer capacities. For lubricant change procedures, refer
to “Transmissions” on page 161.) to “Transmissions” on page 161.)
Check condition and tightness of all mounts. A, B, C, D Check condition and tightness of all mounts. A, B, C, D
Inspect all linkages for wear, binding and full C, D Inspect all linkages for wear, binding and full C, D
engagement in all gears. engagement in all gears.
Inspect and clean breathers. C, D Inspect and clean breathers. C, D
Change air filter on air-shifted transmissions. C, D Change air filter on air-shifted transmissions. C, D
Service select air valve on air-shifted transmissions. C, D Service select air valve on air-shifted transmissions. C, D
Service air shift cover on air-shifted transmissions. C, D Service air shift cover on air-shifted transmissions. C, D
Service range shift valve on T300 series C, D Service range shift valve on T300 series C, D
transmissions. transmissions.
PROPELLER SHAFTS: PROPELLER SHAFTS:
Check tightness of the universal joints. Check for A, B, C, D Check tightness of the universal joints. Check for A, B, C, D
leaks. leaks.
Inspect yokes or flanges for tightness. A, B, C, D Inspect yokes or flanges for tightness. A, B, C, D
Inspect splines for wear or seizure. Arrows at C, D Inspect splines for wear or seizure. Arrows at C, D
splined joints must be in alignment with each other splined joints must be in alignment with each other
to avoid vibration. to avoid vibration.
DRIVELINE RETARDER: DRIVELINE RETARDER:
Inspect rotor air gap and adjust as required. D Inspect rotor air gap and adjust as required. D
59 59
CENTER BEARING: Inspection CENTER BEARING: Inspection

Schedule Schedule
Inspect bearing for wear. Check for loose hanger A, B, C, D Inspect bearing for wear. Check for loose hanger A, B, C, D
bolts, deteriorated or worn insulator or cracked bolts, deteriorated or worn insulator or cracked
support. support.
REAR AXLE AND SUSPENSION: REAR AXLE AND SUSPENSION:

Check for broken spring leaves. A, B, C, D Check for broken spring leaves. A, B, C, D
Check for wheel seal leaks. A, B, C, D Check for wheel seal leaks. A, B, C, D
Check shock absorbers for leakage and damage. A, B, C, D Check shock absorbers for leakage and damage. A, B, C, D
Replace if the shock absorber body is damaged, if Replace if the shock absorber body is damaged, if
the dust tube or end mounts are cracked or if the dust tube or end mounts are cracked or if
leaking is evident. Also, check the upper and lower leaking is evident. Also, check the upper and lower
bushings for wear, deterioration or deformation and bushings for wear, deterioration or deformation and
replace as necessary. replace as necessary.
Check condition of spring and trunnion insulators. B, C, D Check condition of spring and trunnion insulators. B, C, D
Inspect axle housing(s) for leakage or cracks. C, D Inspect axle housing(s) for leakage or cracks. C, D
Remove and clean all magnetic plugs in carrier and C, D Remove and clean all magnetic plugs in carrier and C, D
power divider. Clean magnetic strips and oil trough. power divider. Clean magnetic strips and oil trough.
Check torque rods for damage. Check torque rod C, D Check torque rods for damage. Check torque rod C, D
ball joints for wear or deterioration. Check ball joints for wear or deterioration. Check
rubber-bushed torque rods for unequal rubber rubber-bushed torque rods for unequal rubber
exposure, cracked or ruptured rubber bushings, exposure, cracked or ruptured rubber bushings,
off-center pins or expanded mounting pin holes. off-center pins or expanded mounting pin holes.
Check for broken center bolts, and loose or C, D Check for broken center bolts, and loose or C, D
damaged rebound clips, cap retainers, shackles damaged rebound clips, cap retainers, shackles
and brackets. and brackets.
60 60
REAR AXLE AND SUSPENSION: Inspection REAR AXLE AND SUSPENSION: Inspection
Torque spring clips (U-bolts) (spring and walking C, D Torque spring clips (U-bolts) (spring and walking C, D
beam suspensions). beam suspensions).
On chassis equipped with Reyco suspensions, On chassis equipped with Reyco suspensions,
check and adjust torque of the spring clips check and adjust torque of the spring clips
(U-bolts), equalizer nuts, torque arm bolts (at the (U-bolts), equalizer nuts, torque arm bolts (at the
hangers and axle seats), and torque arm tube hangers and axle seats), and torque arm tube
clamp nuts at each B, C, and D inspection interval. clamp nuts at each B, C, and D inspection interval.
ALL MACK AIR SUSPENSIONS — In addition to ALL MACK AIR SUSPENSIONS — In addition to
the other suspension items outlined in this section, the other suspension items outlined in this section,
the following items must be performed on MACK air the following items must be performed on MACK air
suspensions. suspensions.
Check U-bolt locknut torque. A, B, C, D Check U-bolt locknut torque. A, B, C, D
Check main support member fastener torque: A, B, C, D Check main support member fastener torque: A, B, C, D
AL — Support member to air spring lower mounting AL — Support member to air spring lower mounting
bracket. bracket.
AL II — Support member to cross channel section. AL II — Support member to cross channel section.
MaxLite™ 20–40 and MaxLite™ 20–40 EZ — MaxLite™ 20–40 and MaxLite™ 20–40 EZ —
Support member to crossbeam. Support member to crossbeam.
Check air springs for cracks, gouges, distortion, C, D Check air springs for cracks, gouges, distortion, C, D
bulges and/or chafing and replace as necessary. If bulges and/or chafing and replace as necessary. If
an air spring requires replacement, inspect other an air spring requires replacement, inspect other
areas of the suspension for potential problems. areas of the suspension for potential problems.
Check air suspension air lines for leaks. C, D Check air suspension air lines for leaks. C, D
Check torque of other fasteners as outlined on D Check torque of other fasteners as outlined on D
“OTHER FASTENERS” on page 189. “OTHER FASTENERS” on page 189.
Check functionality of height-control valve. Measure D Check functionality of height-control valve. Measure D
and adjust ride height as necessary. and adjust ride height as necessary.
Remove all wheels. D Remove all wheels. D
61 61
Clean and inspect wheel bearings. D Clean and inspect wheel bearings. D
For chassis equipped with unitized wheel hubs, the For chassis equipped with unitized wheel hubs, the
hubs are sealed and lubricated for life. Do not hubs are sealed and lubricated for life. Do not
disassemble and attempt to repair a unitized wheel disassemble and attempt to repair a unitized wheel
hub. Refer to the specific manufacturer’s service hub. Refer to the specific manufacturer’s service
literature for detailed information. literature for detailed information.
Repack grease-type wheel bearings. D Repack grease-type wheel bearings. D

Inspect condition of brake lining/disc pads. D Inspect condition of brake lining/disc pads. D
Measure and record brake lining thickness. D Measure and record brake lining thickness. D
Inspect, measure and record drum/rotor wear in D Inspect, measure and record drum/rotor wear in D
mm (inches). Compare measurements with mm (inches). Compare measurements with
dimension cast into the drum or rotor. dimension cast into the drum or rotor.
Inspect condition of brake spiders, mounting bolts D Inspect condition of brake spiders, mounting bolts D
and disc calipers. and disc calipers.
Inspect condition of brake shoes. Check lining for D Inspect condition of brake shoes. Check lining for D
flaking, etc. flaking, etc.
Inspect brake cams and bushings (cam brakes). D Inspect brake cams and bushings (cam brakes). D
Replace wheel bearing seals. D Replace wheel bearing seals. D
Fill rear axle to specified level. (See “LUBRICANT D Fill rear axle to specified level. (See “LUBRICANT D
SPECIFICATIONS” on page 267.) SPECIFICATIONS” on page 267.)
It is extremely important to use a retaining It is extremely important to use a retaining

method when working on all spring brake method when working on all spring brake
chambers. The spring is under heavy chambers. The spring is under heavy
compression and can expand rapidly with great compression and can expand rapidly with great
force and cause injury. force and cause injury.
62 62
Check brake air chambers for leakage. Make A, B, C, D Check brake air chambers for leakage. Make A, B, C, D
several brake applications and observe that push several brake applications and observe that push
rods respond quickly and with no indications of rods respond quickly and with no indications of
binding. Refer to the Air and Brake System Service binding. Refer to the Air and Brake System Service
Manual, 16-104, for more detailed maintenance Manual, 16-104, for more detailed maintenance
Measure push rod travel. Stroke should be as short A, B, C, D Measure push rod travel. Stroke should be as short A, B, C, D
as possible without allowing the brakes to drag. as possible without allowing the brakes to drag.
Adjust manual slack adjusters as necessary. Adjust manual slack adjusters as necessary.
Automatic slack adjusters should not require Automatic slack adjusters should not require
periodic adjustments. Refer to the Air and Brake periodic adjustments. Refer to the Air and Brake
System Service Manual, 16-104, for more detailed System Service Manual, 16-104, for more detailed
CARRIER/CARRIERS: CARRIER/CARRIERS:
Inspect for leaks. A, B, C, D Inspect for leaks. A, B, C, D
Check carrier(s) lube level. Add required gear oil, if A, B, C, D Check carrier(s) lube level. Add required gear oil, if A, B, C, D
Check carrier mounting. Check and re-torque C, D Check carrier mounting. Check and re-torque C, D
hidden capscrews (refer to “CARRIER CAPSCREW hidden capscrews (refer to “CARRIER CAPSCREW
TORQUE” on page 180). TORQUE” on page 180).
Remove and clean carrier breather. D Remove and clean carrier breather. D
63 63
AUXILIARY AXLES: AUXILIARY AXLES:
Check wheel bearing lube level and check wheel A, B, C, D Check wheel bearing lube level and check wheel A, B, C, D
seals for leakage. Add oil and repair wheel seals as seals for leakage. Add oil and repair wheel seals as
required. required.
Check condition of tires, tread depth, wear pattern A, B, C, D Check condition of tires, tread depth, wear pattern A, B, C, D
and correct inflation pressure (while tires are cold). and correct inflation pressure (while tires are cold).
Check condition of wheels, rims, wheel studs and A, B, C, D Check condition of wheels, rims, wheel studs and A, B, C, D
nuts. Replace if damaged. Tighten wheel nuts to nuts. Replace if damaged. Tighten wheel nuts to
Lubricate king pins and tie rod ends (steerable A, B, C, D Lubricate king pins and tie rod ends (steerable A, B, C, D
axles). axles).
Check torque of pivot bolts. A, B, C, D Check torque of pivot bolts. A, B, C, D

Check operation of suspension air bag relay B, C, D Check operation of suspension air bag relay B, C, D
valve(s), up/down solenoid valve(s), lift control valve(s), up/down solenoid valve(s), lift control
valve(s), pressure protection valve(s), lift air bag valve(s), pressure protection valve(s), lift air bag
quick release valve(s), brake system relay valve(s) quick release valve(s), brake system relay valve(s)
and brake system quick release valve(s) (if so and brake system quick release valve(s) (if so
equipped). equipped).
Check king pins and bushings for wear. C, D Check king pins and bushings for wear. C, D
Check the suspension and lift air bags for cracks, C, D Check the suspension and lift air bags for cracks, C, D
gouges, distortion, bulges and/or chafing and gouges, distortion, bulges and/or chafing and
replace as necessary. If an air bag requires replace as necessary. If an air bag requires
replacement, inspect other areas of the axle replacement, inspect other areas of the axle
assembly for potential problems. assembly for potential problems.
Clean, inspect and lubricate wheel bearings. D Clean, inspect and lubricate wheel bearings. D
Check fastener torque (air spring bolts [top and D Check fastener torque (air spring bolts [top and D
bottom] and tie rod clamp bolt). bottom] and tie rod clamp bolt).
64 64
TIRES: Inspection TIRES: Inspection

Schedule Schedule
Check condition of tires and proper tire match. A, B, C, D Check condition of tires and proper tire match. A, B, C, D
Check tread depth, wear pattern and correct A, B, C, D Check tread depth, wear pattern and correct A, B, C, D
inflation pressure (while tires are cold). inflation pressure (while tires are cold).
Report any case of uneven or unusual tire wear. A, B, C, D Report any case of uneven or unusual tire wear. A, B, C, D
Remove and replace any damaged tires. Remove and replace any damaged tires.
Check for proper function of central tire inflation A, B, C, D Check for proper function of central tire inflation A, B, C, D
system (if equipped). system (if equipped).
WHEELS/RIMS: WHEELS/RIMS:
Check condition of wheels, rims, wheel studs and A, B, C, D Check condition of wheels, rims, wheel studs and A, B, C, D
nuts. Replace if damaged. nuts. Replace if damaged.
Torque wheel nuts (rim lug nuts on spoke wheels; A, B, C, D Torque wheel nuts (rim lug nuts on spoke wheels; A, B, C, D
wheel lug nuts [inner and outer when applicable] on wheel lug nuts [inner and outer when applicable] on
disc wheels). disc wheels).
Torque chain clearance spacers if the chassis is so A, B, C, D Torque chain clearance spacers if the chassis is so A, B, C, D
equipped. See “Chain Clearance Spacers” on page equipped. See “Chain Clearance Spacers” on page
222. 222.
REAR AXLE FLANGE: REAR AXLE FLANGE:
Torque axle flange nuts to specifications. A, B, C, D Torque axle flange nuts to specifications. A, B, C, D
65 65
FRAME: Inspection FRAME: Inspection

Schedule Schedule
Clean frame and crossmembers. C, D Clean frame and crossmembers. C, D
Inspect side rails, crossmembers and brackets for C, D Inspect side rails, crossmembers and brackets for C, D
looseness, cracks or fretting. looseness, cracks or fretting.
Inspect spring brackets and crossmember Huck C, D Inspect spring brackets and crossmember Huck C, D
bolts or bolts. bolts or bolts.
TRAILER CORD: TRAILER CORD:
Inspect condition of the trailer cord. Look for A, B, C, D Inspect condition of the trailer cord. Look for A, B, C, D
chafing, missing or loose clamps, bad routing or chafing, missing or loose clamps, bad routing or
loose connections. loose connections.
TRAILER HOSES: TRAILER HOSES:
Check that the trailer hoses do not rub against the A, B, C, D Check that the trailer hoses do not rub against the A, B, C, D
cab, frame or any other chassis components. cab, frame or any other chassis components.
Reroute or clamp as required. Inspect glad hands Reroute or clamp as required. Inspect glad hands
for defects that may affect sealing. for defects that may affect sealing.
FIFTH WHEEL: FIFTH WHEEL:
Check fifth wheel mounting, brackets, latching A, B, C, D Check fifth wheel mounting, brackets, latching A, B, C, D
device, body mounts, sills, fastener and sliding device, body mounts, sills, fastener and sliding
mechanism for cracks or fretting. Torque mounting mechanism for cracks or fretting. Torque mounting
bolts. Instructions vary according to make, follow bolts. Instructions vary according to make, follow
manufacturer’s instructions. manufacturer’s instructions.
66 66
PTO/HOIST: Inspection PTO/HOIST: Inspection

Schedule Schedule
Check reservoir fluid level. Add oil, if necessary. A, B, C, D Check reservoir fluid level. Add oil, if necessary. A, B, C, D
Refer to manufacturer’s service literature for Refer to manufacturer’s service literature for
lubricant specifications. lubricant specifications.
Check operation of controls, PTO and hoist. A, B, C, D Check operation of controls, PTO and hoist. A, B, C, D
Inspect condition of mountings, hinges, brackets, B, C, D Inspect condition of mountings, hinges, brackets, B, C, D
linkages and hydraulic units. linkages and hydraulic units.
SAFETY EQUIPMENT: SAFETY EQUIPMENT:
Check pressure on fire extinguisher gauge. Dial A, B, C, D Check pressure on fire extinguisher gauge. Dial A, B, C, D
should indicate pressure in OK zone. should indicate pressure in OK zone.
On chassis in interstate commerce, check for ICC A, B, C, D On chassis in interstate commerce, check for ICC A, B, C, D
kit containing flags, reflectors, fuses, etc. kit containing flags, reflectors, fuses, etc.
FLAPS: FLAPS:
Check condition and mounting of flaps. Replace, if A, B, C, D Check condition and mounting of flaps. Replace, if A, B, C, D
67 67
NOTES NOTES
68 68
SPECIFIC MAINTENANCE SPECIFIC MAINTENANCE

FOR COMPONENTS NOT FOR COMPONENTS NOT
MANUFACTURED MANUFACTURED
BY MACK TRUCKS BY MACK TRUCKS
CONSULT VENDOR SERVICE CONSULT VENDOR SERVICE
PUBLICATIONS PUBLICATIONS
4 4
Figure 4 — Specific Maintenance Figure 4 — Specific Maintenance
69 69
FASTENER SIZES, TYPES AND GRADES . . . . . . . . . 71 FASTENER SIZES, TYPES AND GRADES . . . . . . . . . 71
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . 105 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . 105
HOSE CLAMP TORQUES . . . . . . . . . . . . . . . . . . . . . . 110 HOSE CLAMP TORQUES . . . . . . . . . . . . . . . . . . . . . . 110
AIR CONDITIONER MAINTENANCE . . . . . . . . . . . . . 111 AIR CONDITIONER MAINTENANCE . . . . . . . . . . . . . 111
AIR CLEANER MAINTENANCE . . . . . . . . . . . . . . . . . 113 AIR CLEANER MAINTENANCE . . . . . . . . . . . . . . . . . 113
TURBOCHARGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 TURBOCHARGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DIESEL PARTICULATE FILTER (DPF) . . . . . . . . . . . . 119 DIESEL PARTICULATE FILTER (DPF) . . . . . . . . . . . . 119
CMCAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 CMCAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 133 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 133
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . 179 STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . 179
CARRIER CAPSCREW TORQUE . . . . . . . . . . . . . . . . 180 CARRIER CAPSCREW TORQUE . . . . . . . . . . . . . . . . 180
FRONT AXLE STATIC SHAKE TEST . . . . . . . . . . . . . 182 FRONT AXLE STATIC SHAKE TEST . . . . . . . . . . . . . 182
SPRING CLIP (U-BOLT) TORQUE . . . . . . . . . . . . . . . 183 SPRING CLIP (U-BOLT) TORQUE . . . . . . . . . . . . . . . 183
MACK AIR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . 187 MACK AIR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . 187
AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
AUXILIARY AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 AUXILIARY AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
WHEEL TORQUE PROCEDURES . . . . . . . . . . . . . . . 215 WHEEL TORQUE PROCEDURES . . . . . . . . . . . . . . . 215
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 224 TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 224
TIRE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 TIRE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
DRIVELINE RETARDER . . . . . . . . . . . . . . . . . . . . . . . 230 DRIVELINE RETARDER . . . . . . . . . . . . . . . . . . . . . . . 230
AIR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 232 AIR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 232
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 235 BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 235
CAB MOUNT MAINTENANCE — LEU AND CAB MOUNT MAINTENANCE — LEU AND
MRU MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 MRU MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 247 CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 247
VALVE AND UNIT INJECTOR ADJUSTMENT . . . . . . 258 VALVE AND UNIT INJECTOR ADJUSTMENT . . . . . . 258
BRAKE DIAGNOSTIC CHART . . . . . . . . . . . . . . . . . . . 259 BRAKE DIAGNOSTIC CHART . . . . . . . . . . . . . . . . . . . 259
70 70
FASTENER SIZES, TYPES AND GRADES FASTENER SIZES, TYPES AND GRADES
Fastener Sizes and Types Fastener Sizes and Types
The first and most important fact that the technician must know about a The first and most important fact that the technician must know about a
fastener is whether it is a U.S. (Inch System) or a metric thread. Next is fastener is whether it is a U.S. (Inch System) or a metric thread. Next is
the size of the fastener, which is usually determined by the diameter of the size of the fastener, which is usually determined by the diameter of
the shank, the length of the fastener, which is usually measured from the shank, the length of the fastener, which is usually measured from
the bottom of the head to the end of the thread, and the pitch of the the bottom of the head to the end of the thread, and the pitch of the
threads. threads.
The pitch of U.S. (Inch System) fasteners is measured by determining The pitch of U.S. (Inch System) fasteners is measured by determining
the number of threads per inch. The two pitches commonly used in the number of threads per inch. The two pitches commonly used in
vehicles are coarse threads, officially called Unified National Coarse vehicles are coarse threads, officially called Unified National Coarse
(UNC), and fine threads, officially called Unified National Fine (UNF). (UNC), and fine threads, officially called Unified National Fine (UNF).
The pitch of metric fasteners is measured by determining the number The pitch of metric fasteners is measured by determining the number
of threads per millimeter. For example, a bolt with 0.8 pitch would have of threads per millimeter. For example, a bolt with 0.8 pitch would have
125 threads in a 100 millimeter section (100 mm divided by 125 threads in a 100 millimeter section (100 mm divided by
125 threads equals 0.8), and a bolt with 1.0 pitch would have 125 threads equals 0.8), and a bolt with 1.0 pitch would have
100 threads in a 100 millimeter section. Pitch may be measured 100 threads in a 100 millimeter section. Pitch may be measured
directly using a ruler and counting the threads. Also, thread pitch directly using a ruler and counting the threads. Also, thread pitch
gauges are available for both U.S. and metric threads, which makes it gauges are available for both U.S. and metric threads, which makes it
easy to check the pitch of a fastener. easy to check the pitch of a fastener.
71 71
5 5
Figure 5 — Fastener Identification Figure 5 — Fastener Identification
72 72
Fastener Grades Fastener Grades

A fastener must be strong enough to do the intended job. U.S. and A fastener must be strong enough to do the intended job. U.S. and
metric systems both separate their fasteners into grades according to metric systems both separate their fasteners into grades according to
strength and quality. In the U.S. system, slash marks are used on bolt strength and quality. In the U.S. system, slash marks are used on bolt
heads to indicate grade. SAE Grade 1 and 2 use no slash marks. heads to indicate grade. SAE Grade 1 and 2 use no slash marks.
These “hardware grades” are used only in the least demanding These “hardware grades” are used only in the least demanding
applications. SAE Grade 5 uses three slash marks on the head. These applications. SAE Grade 5 uses three slash marks on the head. These
are most commonly used for vehicle applications. SAE Grade 8 uses are most commonly used for vehicle applications. SAE Grade 8 uses
six slash marks on the head. These high strength bolts are used where six slash marks on the head. These high strength bolts are used where
conditions require very high torque. conditions require very high torque.
Locknuts are also divided into grades called A, B and C. Grade A Locknuts are also divided into grades called A, B and C. Grade A
locknuts are intended for use with SAE Grade 1 and 2 bolts, and the locknuts are intended for use with SAE Grade 1 and 2 bolts, and the
nuts are not marked for identification. Grade B locknuts are intended nuts are not marked for identification. Grade B locknuts are intended
for use with SAE Grade 5 bolts and are marked either with the letter “B” for use with SAE Grade 5 bolts and are marked either with the letter “B”
or three equally spaced symbols (dot, line, letter or other character). or three equally spaced symbols (dot, line, letter or other character).
Grade C locknuts are intended for use with SAE Grade 8 bolts and are Grade C locknuts are intended for use with SAE Grade 8 bolts and are
marked with either the letter “C” or six equally spaced symbols (dot, marked with either the letter “C” or six equally spaced symbols (dot,
line, letter or other character). Another marking alternative is having line, letter or other character). Another marking alternative is having
notches cut circumferentially into each of the six corners of the locknut notches cut circumferentially into each of the six corners of the locknut
at approximately mid-height, one row of notches for Grade B and two at approximately mid-height, one row of notches for Grade B and two
rows for Grade C. rows for Grade C.
Metric threaded fasteners are also separated into grades according to Metric threaded fasteners are also separated into grades according to
strength and quality. Bolts commonly used in vehicles are metric strength and quality. Bolts commonly used in vehicles are metric
Class 8.8, metric Class 9.8, and metric Class 10.9. These metric bolts Class 8.8, metric Class 9.8, and metric Class 10.9. These metric bolts
are identified by the class number stamped on the head of the bolt. are identified by the class number stamped on the head of the bolt.
Metric nuts commonly used are Class 9 and Class 10. The metric nuts Metric nuts commonly used are Class 9 and Class 10. The metric nuts
also have the class number stamped on them for easy identification. also have the class number stamped on them for easy identification.
73 73
6 6
Figure 6 — Fastener Grades Figure 6 — Fastener Grades
74 74
Potential external/internal thread mismatch Potential external/internal thread mismatch

conditions may occur with certain metric thread/ conditions may occur with certain metric thread/
inch thread fastener combinations, and with inch thread fastener combinations, and with
fastener combinations involving incompatible fastener combinations involving incompatible
metric fastener systems. A given thread mismatch metric fastener systems. A given thread mismatch
can result in thread stripping and/or assembly can result in thread stripping and/or assembly
weakness leading to potential service failure, weakness leading to potential service failure,
thereby rendering a vehicle non-operational and/or thereby rendering a vehicle non-operational and/or
unsafe for operation. unsafe for operation.
The specific external/internal thread combinations The specific external/internal thread combinations
from which such problems can result are identified from which such problems can result are identified
and set forth below as thread combinations which and set forth below as thread combinations which
must not be utilized in service. must not be utilized in service.
Incompatible Metric vs. Metric Fastener Systems Incompatible Metric vs. Metric Fastener Systems
Potential external/internal thread mismatch can result from use of Potential external/internal thread mismatch can result from use of
fasteners from incompatible metric fastener systems. The resulting fasteners from incompatible metric fastener systems. The resulting
condition of faulty thread engagement typically produces thread condition of faulty thread engagement typically produces thread
stripping and/or assembly weakness leading to possible service failure. stripping and/or assembly weakness leading to possible service failure.
Domestically procured MACK models may use metric fasteners Domestically procured MACK models may use metric fasteners
derived from differing metric fastener systems. It is therefore imperative derived from differing metric fastener systems. It is therefore imperative
to identify and use only those fasteners designated for use with the to identify and use only those fasteners designated for use with the
respective vehicle being serviced. Refer to fastener information respective vehicle being serviced. Refer to fastener information
provided in the applicable vehicle service manual. provided in the applicable vehicle service manual.
Inch Thread vs. Metric Thread Fastener Combinations Inch Thread vs. Metric Thread Fastener Combinations
Contributing to Thread Stripping Contributing to Thread Stripping
The following combinations of inch and metric screws and nuts (or The following combinations of inch and metric screws and nuts (or
tapped holes) can be given a finger start (at least two full turns), but will tapped holes) can be given a finger start (at least two full turns), but will
strip if fully assembled. strip if fully assembled.
75 75
INCH THREAD VS. METRIC THREAD FASTENER COMBINATIONS INCH THREAD VS. METRIC THREAD FASTENER COMBINATIONS
CONTRIBUTING TO THREAD STRIPPING CONTRIBUTING TO THREAD STRIPPING
INCH SCREWS METRIC NUTS INCH SCREWS METRIC NUTS
4-40 M3 x 0.5 4-40 M3 x 0.5
5/16-18 M8 x 1.25 5/16-18 M8 x 1.25
*5/16-24 M8 x 1.25 *5/16-24 M8 x 1.25
3/8-16 *M10 x 1.25 3/8-16 *M10 x 1.25
*3/8-24 M10 x 1.5 *M10 x 1.25 *M10 x 1.0 *3/8-24 M10 x 1.5 *M10 x 1.25 *M10 x 1.0
7/16-14 *M12 x 1.25 7/16-14 *M12 x 1.25
*7/16-20 M12 x 1.75 *M12 x 1.5 *7/16-20 M12 x 1.75 *M12 x 1.5
*1/2-20 M14 x 2 *1/2-20 M14 x 2
*5/8-18 *M16 x 1.5 *5/8-18 *M16 x 1.5
*7/8-14 M24 x 3 *7/8-14 M24 x 3
*1-12 M27 x 3 *1-12 M27 x 3
METRIC SCREWS INCH NUTS METRIC SCREWS INCH NUTS
M3 x 0.5 5-40 M3 x 0.5 5-40
M6 x 1.0 1/4-20 M6 x 1.0 1/4-20
M6 x 1.0 *1/4-28 M6 x 1.0 *1/4-28
*M8 x 1.0 *5/16-24 *M8 x 1.0 *5/16-24
M10 x 1.5 7/16-14 M10 x 1.5 7/16-14
*M10 x 1.25 7/16-14 *M10 x 1.25 7/16-14
*M10 x 1.0 7/16-14 *M10 x 1.0 7/16-14
M12 x 1.75 1/2-13 M12 x 1.75 1/2-13
M12 x 1.75 *1/2-20 M12 x 1.75 *1/2-20
*M12 x 1.5 1/2-13 *M12 x 1.5 1/2-13
*M12 x 1.5 *1/2-20 *M12 x 1.5 *1/2-20
*M12 x 1.25 1/2-13 *M12 x 1.25 1/2-13
M14 x 2 9/16-12 M14 x 2 9/16-12
*M14 x 1.5 *9/16-18 *M14 x 1.5 *9/16-18
*M16 x 1.5 *5/8-18 *M16 x 1.5 *5/8-18
*M24 x 2 1-8 *M24 x 2 1-8
* Fine Thread * Fine Thread
76 76
Contributing to Assembly Weakness Contributing to Assembly Weakness
The following combinations of inch and metric screws and nuts (or The following combinations of inch and metric screws and nuts (or
tapped holes) can be fully assembled, but the resultant assembly will tapped holes) can be fully assembled, but the resultant assembly will
be 25% to 60% weaker than required. Service failure of the assembly be 25% to 60% weaker than required. Service failure of the assembly
is probable. is probable.
77 77
INCH THREAD VS. METRIC THREAD FASTENER COMBINATIONS INCH THREAD VS. METRIC THREAD FASTENER COMBINATIONS
CONTRIBUTING TO ASSEMBLY WEAKNESS CONTRIBUTING TO ASSEMBLY WEAKNESS
INCH SCREWS METRIC NUTS INCH SCREWS METRIC NUTS

*4-48 M3 x 0.5 *4-48 M3 x 0.5
5-40 M3.5 x 0.6 5-40 M3.5 x 0.6
6-40 M3.5 x 0.6 6-40 M3.5 x 0.6
*8-36 M4 x 0.7 *8-36 M4 x 0.7
*10-32 M5 x 0.8 *10-32 M5 x 0.8
12-24 M6 x 1.0 12-24 M6 x 1.0
*1/4-28 M7 x 1.0 *1/4-28 M7 x 1.0
3/8-16 M10 x 1.5 3/8-16 M10 x 1.5
7/16-14 M12 x 1.75 7/16-14 M12 x 1.75
1/2-13 M14 x 2 1/2-13 M14 x 2
3/4-10 M20 x 2.5 3/4-10 M20 x 2.5
*3/4-16 *M20 x 1.5 *3/4-16 *M20 x 1.5
7/8-9 M24 x 3 7/8-9 M24 x 3
METRIC SCREWS INCH NUTS METRIC SCREWS INCH NUTS

M3 x 0.5 *5-44 M3 x 0.5 *5-44
M3.5 x 0.6 *6-40 M3.5 x 0.6 *6-40
M4 x 0.7 8-32 M4 x 0.7 8-32
M4 x 0.7 *8-36 M4 x 0.7 *8-36
M5 x 0.8 *10-32 M5 x 0.8 *10-32
M5 x 0.8 12-24 M5 x 0.8 12-24
M5 x 0.8 *12-28 M5 x 0.8 *12-28
*M12 x 1.25 *1/2-20 *M12 x 1.25 *1/2-20
M18 x 2.5 3/4-10 M18 x 2.5 3/4-10
*M18 x 1.5 *3/4-16 *M18 x 1.5 *3/4-16
M24 x 3 1-8 M24 x 3 1-8
M24 x 2 *1-12 M24 x 2 *1-12
* Fine Thread * Fine Thread
78 78
DRIVE BELTS DRIVE BELTS

Poly V-belts and automatic belt tensioners are used on MACK MP7 and Poly V-belts and automatic belt tensioners are used on MACK MP7 and
MP8 engines for both the main drive and accessory drive belts. MP8 engines for both the main drive and accessory drive belts.
Condition of the automatic belt tensioners should be checked as Condition of the automatic belt tensioners should be checked as
outlined in this manual, at each A, B, C and D inspection intervals. outlined in this manual, at each A, B, C and D inspection intervals.
Drive Belt Replacement Intervals Drive Belt Replacement Intervals

Replacement intervals for both the fan and accessory drive belts are as Replacement intervals for both the fan and accessory drive belts are as
follows: follows:
Fan Drive Belts — Fan Drive Belts —

앫 Highway Usage: 500 000 km/300,000 miles or a maximum of 앫 Highway Usage: 500 000 km/300,000 miles or a maximum of
앫 Vocational Usage: 240 000 km/150,000 miles or a maximum of 앫 Vocational Usage: 240 000 km/150,000 miles or a maximum of
Accessory Drive Belts — Accessory Drive Belts —

앫 Highway Usage: 500 000 km/300,000 miles or a maximum of 앫 Highway Usage: 500 000 km/300,000 miles or a maximum of
앫 Vocational Usage: 240 000 km/150,000 miles or a maximum of 앫 Vocational Usage: 240 000 km/150,000 miles or a maximum of
If belts squeak or squeal, clean with hydraulic brake If belts squeak or squeal, clean with hydraulic brake
fluid or an approved cleaning fluid. Replace belts that fluid or an approved cleaning fluid. Replace belts that
are severely worn or frayed. are severely worn or frayed.
79 79
RIB CRACKING RIB CRACKING

An in-service poly V-belt will go through several phases of cracking An in-service poly V-belt will go through several phases of cracking
during its life. After an extended time in service, minor rib cracks may during its life. After an extended time in service, minor rib cracks may
appear, usually one or two cracks per inch. This cracking is normal. appear, usually one or two cracks per inch. This cracking is normal.
7 7
Figure 7 — Belt with Minor Rib Cracks Figure 7 — Belt with Minor Rib Cracks
80 80
Belts should not be replaced unless the ribs exhibit severe multiple Belts should not be replaced unless the ribs exhibit severe multiple
cracking as shown below. Multiple cracking will lead to rib chunking. cracking as shown below. Multiple cracking will lead to rib chunking.
8 8
Figure 8 — Belt with Multiple Cracking Figure 8 — Belt with Multiple Cracking
9 9
Figure 9 — Belt with Severe Cracking and Rib Chunking Figure 9 — Belt with Severe Cracking and Rib Chunking
81 81
RIB SIDEWALL GLAZING RIB SIDEWALL GLAZING

When the belt ribs appear to have a shiny surface that is hard and When the belt ribs appear to have a shiny surface that is hard and
brittle, it is usually an indication of belt slippage. This is attributed to brittle, it is usually an indication of belt slippage. This is attributed to
inadequate tension and/or extreme temperature. Both these conditions inadequate tension and/or extreme temperature. Both these conditions
will lead to severe cracking and belt failure, often with little advance will lead to severe cracking and belt failure, often with little advance
warning. If this occurs, locate the cause and correct before installing a warning. If this occurs, locate the cause and correct before installing a
new belt. new belt.
BELT WEAR BELT WEAR

Accelerated wear on any part of the belt (fabric backing, tensile cord or Accelerated wear on any part of the belt (fabric backing, tensile cord or
rib rubber) is a concern and should be investigated for cause, and rib rubber) is a concern and should be investigated for cause, and
corrected before installing a new belt. corrected before installing a new belt.
Possible Causes of Accelerated Belt Wear Possible Causes of Accelerated Belt Wear
앫 Drive Misalignment — Belt performance will be adversely 앫 Drive Misalignment — Belt performance will be adversely
affected when misalignment exceeds 1/16 inch for every affected when misalignment exceeds 1/16 inch for every
12 inches of belt span. 12 inches of belt span.
앫 Belt Length — Must be correct. 앫 Belt Length — Must be correct.
앫 Environmental Conditions — Temperature, exposure to engine 앫 Environmental Conditions — Temperature, exposure to engine
fluids, etc. fluids, etc.
앫 Abrasive Materials — Small stones, metal shavings, etc. 앫 Abrasive Materials — Small stones, metal shavings, etc.
10 10
Figure 10 — Belt Exhibiting Accelerated Wear Figure 10 — Belt Exhibiting Accelerated Wear
82 82
FOREIGN OBJECTS FOREIGN OBJECTS

Any object protruding in the path of the belt drive and contacting the Any object protruding in the path of the belt drive and contacting the
belt will cause damage and eventual failure. Locate the object before belt will cause damage and eventual failure. Locate the object before
installing a new belt. (See Figure 11.) installing a new belt. (See Figure 11.)
11 11
Figure 11 — Damage from Object Protruding in Belt Path Figure 11 — Damage from Object Protruding in Belt Path
83 83
NOISE, VIBRATION AND HARSHNESS (NVH) NOISE, VIBRATION AND HARSHNESS (NVH)
Poly V-belt drive systems were designed to prevent Noise, Vibration Poly V-belt drive systems were designed to prevent Noise, Vibration
and Harshness (NVH) problems. Field problems, however, which may and Harshness (NVH) problems. Field problems, however, which may
be related to NVH causes occasionally occur. be related to NVH causes occasionally occur.
Possible Causes Possible Causes
Insufficient belt tension may create a high-pitched howl (squeal) or Insufficient belt tension may create a high-pitched howl (squeal) or
rasping sound during engine acceleration or deceleration. rasping sound during engine acceleration or deceleration.
Misalignment may cause a chirping noise, especially at, or near, idle Misalignment may cause a chirping noise, especially at, or near, idle
speed. Rigid bracketing of accessories is a must for reasonably speed. Rigid bracketing of accessories is a must for reasonably
vibration-free belt spans. Some span vibration is to be expected during vibration-free belt spans. Some span vibration is to be expected during
the range of engine speed and accessory loading. the range of engine speed and accessory loading.
Failure to follow recommended application Failure to follow recommended application

information and recommended procedures for information and recommended procedures for
installation, care maintenance and storage of belts installation, care maintenance and storage of belts
may result in failure to perform properly and may may result in failure to perform properly and may
result in damage to property and serious bodily result in damage to property and serious bodily
injury. Make sure the belt selected for any injury. Make sure the belt selected for any
application is recommended for that service. application is recommended for that service.
84 84
DRIVE BELT INSTALLATION DRIVE BELT INSTALLATION

To install a poly V-belt, swing the automatic tensioner to the full sprung To install a poly V-belt, swing the automatic tensioner to the full sprung
position (fully toward the install stop), then place the belt over the position (fully toward the install stop), then place the belt over the
pulleys. Slowly return the automatic tensioner back to its original pulleys. Slowly return the automatic tensioner back to its original
position. Do not allow the tensioner to snap against the stops. For position. Do not allow the tensioner to snap against the stops. For
proper belt routing, refer to the following belt routing diagrams. Before proper belt routing, refer to the following belt routing diagrams. Before
installing the new belt, ensure that the pulley grooves are clean and installing the new belt, ensure that the pulley grooves are clean and
free of debris. free of debris.
Certain GU and CXU model chassis equipped MP7 engines utilize a Certain GU and CXU model chassis equipped MP7 engines utilize a
10-rib belt on 12-rib pulleys. When replacing the belt, the belt must be 10-rib belt on 12-rib pulleys. When replacing the belt, the belt must be
installed against the rear face of the pulley (edge of pulley closest to installed against the rear face of the pulley (edge of pulley closest to
the engine) as shown in the illustration below. the engine) as shown in the illustration below.
12 12

Figure 12 — 10-Rib Belt Installation on 12-Rib Pulley Figure 12 — 10-Rib Belt Installation on 12-Rib Pulley
1. Install 10-rib belt against rear edge of 12-rib pulley. 1. Install 10-rib belt against rear edge of 12-rib pulley.
85 85
Drive Belt Routing — MACK MP7 and MP8 engines, all models. Drive Belt Routing — MACK MP7 and MP8 engines, all models.
13 13

Figure 13 — Drive Belt Routing — MP7 and MP8 Engines Figure 13 — Drive Belt Routing — MP7 and MP8 Engines
1. Crankshaft Pulley 7. Idler Pulley (when applicable) 1. Crankshaft Pulley 7. Idler Pulley (when applicable)
2. Automatic Tensioner 8. Accessory Drive Belt 2. Automatic Tensioner 8. Accessory Drive Belt
3. Idler Pulley 9. Automatic Tensioner 3. Idler Pulley 9. Automatic Tensioner
4. Water Pump 10. Alternator 4. Water Pump 10. Alternator
5. Main Drive Belt 11. Air Conditioner Compressor (if 5. Main Drive Belt 11. Air Conditioner Compressor (if
6. Fan Drive equipped) 6. Fan Drive equipped)
86 86
Automatic Belt Tensioner Maintenance Automatic Belt Tensioner Maintenance

The automatic belt tensioner is designed to maintain proper belt The automatic belt tensioner is designed to maintain proper belt
tension throughout the life of the tensioner. The belt tensioner cannot tension throughout the life of the tensioner. The belt tensioner cannot
be adjusted or repaired. At each D inspection interval or once per year, be adjusted or repaired. At each D inspection interval or once per year,
whichever occurs first, check the following: whichever occurs first, check the following:
앫 With the belt on the drive, check the following: 앫 With the belt on the drive, check the following:
— Check to see if the tensioner is resting against the install — Check to see if the tensioner is resting against the install
stop or the free-arm stop. If the tensioner is resting against stop or the free-arm stop. If the tensioner is resting against
either stop, the tensioner must be replaced. either stop, the tensioner must be replaced.
14 14
Figure 14 — Tensioner Install Stop and Free-Arm Stop (Main Drive Belt Figure 14 — Tensioner Install Stop and Free-Arm Stop (Main Drive Belt
Tensioner Shown) Tensioner Shown)
1. Install Stop 2. Free-Arm Stop 1. Install Stop 2. Free-Arm Stop
87 87
— On main drive belt tensioners, check belt tracking. If the belt — On main drive belt tensioners, check belt tracking. If the belt
is tracking all the way to one side of the tensioner pulley is tracking all the way to one side of the tensioner pulley
(either the front- or back-side), replace the tensioner. Belt (either the front- or back-side), replace the tensioner. Belt
tracking can be determined by looking at the witness mark tracking can be determined by looking at the witness mark
(the shiny area on the pulley where the belt rides). The (the shiny area on the pulley where the belt rides). The
witness mark should be approximately the same width of witness mark should be approximately the same width of
the belt. the belt.
15 15

Figure 15 — Main Drive Belt Tensioner Belt Tracking Witness Mark Figure 15 — Main Drive Belt Tensioner Belt Tracking Witness Mark
1. Acceptable (Witness Mark 2. Not Acceptable (Witness Mark 1. Acceptable (Witness Mark 2. Not Acceptable (Witness Mark
Approximately Same Width as Tracking Off Edge of Pulley) Approximately Same Width as Tracking Off Edge of Pulley)
Belt) Belt)
88 88
앫 Remove the belt by using a 3/8 inch breaker bar to pull the 앫 Remove the belt by using a 3/8 inch breaker bar to pull the
tensioner back to the install stop. Slowly return the tensioner to tensioner back to the install stop. Slowly return the tensioner to
the free-arm stop. the free-arm stop.
앫 With the belt removed, use the breaker bar to slowly pull the 앫 With the belt removed, use the breaker bar to slowly pull the
tensioner from the free-arm stop to the install stop and then tensioner from the free-arm stop to the install stop and then
slowly releasing it back to the free-arm stop. Any excessive slowly releasing it back to the free-arm stop. Any excessive
roughness or hesitancy noticed while performing this check roughness or hesitancy noticed while performing this check
indicates that the tensioner must be replaced. indicates that the tensioner must be replaced.
앫 Check for metal-to-metal contact as follows: 앫 Check for metal-to-metal contact as follows:
— Check for contact between the arm and the spring case. — Check for contact between the arm and the spring case.
Replace if metal-to-metal contact is seen. Replace if metal-to-metal contact is seen.
16 16
Figure 16 — Checking for Contact Between Arm and Spring Case Figure 16 — Checking for Contact Between Arm and Spring Case
89 89
— Check for metal-to-metal contact between the arm and the — Check for metal-to-metal contact between the arm and the
end cap. Replace if contact is seen. end cap. Replace if contact is seen.
17 17
Figure 17 — Checking for Contact Between Arm and End Cap Figure 17 — Checking for Contact Between Arm and End Cap
앫 Check for cracks in the tensioner body or for broken stops on the 앫 Check for cracks in the tensioner body or for broken stops on the
spring case. If either is seen, replace the tensioner. spring case. If either is seen, replace the tensioner.
앫 Reinstall the belt making sure that the belt is properly seated in 앫 Reinstall the belt making sure that the belt is properly seated in
the grooves of ALL pulleys. the grooves of ALL pulleys.
If an automatic belt tensioner must be replaced, make If an automatic belt tensioner must be replaced, make
sure that the proper tensioner is used. Tensioner sure that the proper tensioner is used. Tensioner
spring tension varies by engine and chassis model. Do spring tension varies by engine and chassis model. Do
not substitute one tensioner part number for another, not substitute one tensioner part number for another,
as drive belt failure can result. as drive belt failure can result.
90 90
COOLING SYSTEM COOLING SYSTEM

The cooling system plays an important role in overall engine The cooling system plays an important role in overall engine
performance by keeping the engine within the normal operating performance by keeping the engine within the normal operating
temperature range — hot enough for efficient combustion, and cool temperature range — hot enough for efficient combustion, and cool
enough to prevent engine damage caused by overheating. Good enough to prevent engine damage caused by overheating. Good
preventive maintenance practices, along with monitoring cooling preventive maintenance practices, along with monitoring cooling
system performance, go a long way in preventing engine damage that system performance, go a long way in preventing engine damage that
could result from cooling system problems. The maintenance items could result from cooling system problems. The maintenance items
and tests outlined in this section should be performed at the intervals and tests outlined in this section should be performed at the intervals
specified to ensure optimum performance from the cooling system. specified to ensure optimum performance from the cooling system.
Surge Tank/Radiator Pressure Cap Surge Tank/Radiator Pressure Cap

At every C and D inspection, check the condition of the surge tank/ At every C and D inspection, check the condition of the surge tank/
radiator cap gasket. Also, pressure-test the cap using a suitable radiator cap gasket. Also, pressure-test the cap using a suitable
cooling system and radiator cap tester. Radiator cap pressure cooling system and radiator cap tester. Radiator cap pressure
specifications are as follows: specifications are as follows:
앫 MP8 Engines — 16-lb. pressure cap 앫 MP8 Engines — 16-lb. pressure cap
앫 MP7 Engines — 16-lb. pressure cap 앫 MP7 Engines — 16-lb. pressure cap
Thermostat Thermostat
Check thermostat operation, particularly during cold weather, to make Check thermostat operation, particularly during cold weather, to make
sure the thermostat closes fully, does not allow any leakage and does sure the thermostat closes fully, does not allow any leakage and does
not open too soon. Also, the thermostat seal should be checked for not open too soon. Also, the thermostat seal should be checked for
leakage. A faulty thermostat and/or coolant leaking past the thermostat leakage. A faulty thermostat and/or coolant leaking past the thermostat
can cause engine overcooling and insufficient cab heat. can cause engine overcooling and insufficient cab heat.
91 91
Coolant Mixture Coolant Mixture

The coolant mixture should be tested to ensure that the coolant is The coolant mixture should be tested to ensure that the coolant is
maintained at the proper level of protection. A proper coolant mixture, maintained at the proper level of protection. A proper coolant mixture,
which is essential to the cooling system, contains the following: which is essential to the cooling system, contains the following:
앫 Quality Water — Water meeting the minimum acceptable 앫 Quality Water — Water meeting the minimum acceptable
specifications listed in the following table, must be used in the specifications listed in the following table, must be used in the
cooling system. cooling system.
Property Limit ASTM Test Method Property Limit ASTM Test Method
Chloride (Cl), gr/gal 2.4 (40) max. D512b, D512d, D4327 Chloride (Cl), gr/gal 2.4 (40) max. D512b, D512d, D4327
(ppm) (ppm)
Sulfate (SO4), gr/gal 5.9 (100) max. D516b, D516d, D4327 Sulfate (SO4), gr/gal 5.9 (100) max. D516b, D516d, D4327
(ppm) (ppm)
Total Hardness, gr/gal 10 (170) max. D1126b Total Hardness, gr/gal 10 (170) max. D1126b
(ppm) (ppm)
Total Solids, gr/gal (ppm) 20 (340) D1293 Total Solids, gr/gal (ppm) 20 (340) D1293
Water tests can be performed by any reputable testing laboratory. Water tests can be performed by any reputable testing laboratory.
If water meeting the above specifications is not available, use If water meeting the above specifications is not available, use
de-ionized or distilled water rather than ordinary tap water to de-ionized or distilled water rather than ordinary tap water to
minimize the adverse effects of minerals in the water. minimize the adverse effects of minerals in the water.
앫 Antifreeze — Heavy-duty diesel engine ethylene glycol- or 앫 Antifreeze — Heavy-duty diesel engine ethylene glycol- or
propylene glycol-based coolant must be used in the cooling propylene glycol-based coolant must be used in the cooling
system. The standard factory-fill coolant is a 40/60 mixture of system. The standard factory-fill coolant is a 40/60 mixture of
ethylene glycol-based coolant/quality water. Refer to ethylene glycol-based coolant/quality water. Refer to
“ANTIFREEZE SPECIFICATIONS” on page 284 for antifreeze “ANTIFREEZE SPECIFICATIONS” on page 284 for antifreeze
92 92
Heavy-duty coolant is required, regardless if the Heavy-duty coolant is required, regardless if the
coolant being used is ethylene glycol, propylene glycol coolant being used is ethylene glycol, propylene glycol
or organic acid technology (OAT). DO NOT use or organic acid technology (OAT). DO NOT use
high-silicate automotive types of coolant, as these high-silicate automotive types of coolant, as these
coolants are not compatible with the supplemental coolants are not compatible with the supplemental
coolant additives used in heavy-duty coolants. Use of coolant additives used in heavy-duty coolants. Use of
high-silicate automotive types of coolant can cause high-silicate automotive types of coolant can cause
radiator plugging, resulting in engine damage. radiator plugging, resulting in engine damage.
앫 Supplemental Coolant Additives (SCAs) — Supplemental 앫 Supplemental Coolant Additives (SCAs) — Supplemental
Coolant Additives are chemicals added to the coolant mixture that Coolant Additives are chemicals added to the coolant mixture that
maintain nitrite and pH levels within a specific range. SCAs maintain nitrite and pH levels within a specific range. SCAs
protect against corrosion, pitting and cavitation erosion. protect against corrosion, pitting and cavitation erosion.
STANDARD FACTORY-FILL COOLANT STANDARD FACTORY-FILL COOLANT

The standard factory-fill coolant is a fuchsia (pinkish/purple), The standard factory-fill coolant is a fuchsia (pinkish/purple),
pre-charged ethylene glycol-based product. A pre-charged coolant is pre-charged ethylene glycol-based product. A pre-charged coolant is
one that contains an initial charge of SCAs so that the nitrite one that contains an initial charge of SCAs so that the nitrite
concentration is quickly brought up to the proper level. However, the concentration is quickly brought up to the proper level. However, the
SCA package depletes over time, making it necessary to add SCA package depletes over time, making it necessary to add
additional SCAs during the life of the coolant. additional SCAs during the life of the coolant.
OPTIONAL COOLANTS OPTIONAL COOLANTS

Optional MACK-approved coolants are also available at the factory. Optional MACK-approved coolants are also available at the factory.
These optional coolants include propylene glycol-based and extended- These optional coolants include propylene glycol-based and extended-
life coolants. It is the vehicle owner’s responsibility to know the life coolants. It is the vehicle owner’s responsibility to know the
type of coolant used in the cooling system and understand the type of coolant used in the cooling system and understand the
manufacturer’s recommended service procedures. manufacturer’s recommended service procedures.
Texaco Extended-Life coolants are approved for use in Texaco Extended-Life coolants are approved for use in
MACK diesel engines. MACK diesel engines.
93 93
Fuchsia-colored coolants are NOT extended-life Fuchsia-colored coolants are NOT extended-life
coolants. coolants.
TRADITIONAL COOLANTS VS. EXTENDED-LIFE COOLANTS TRADITIONAL COOLANTS VS. EXTENDED-LIFE COOLANTS
Traditional coolants are ethylene or propylene glycol-based coolants Traditional coolants are ethylene or propylene glycol-based coolants
that require the periodic addition of SCAs during the life of the coolant that require the periodic addition of SCAs during the life of the coolant
so that the level of protection is maintained. so that the level of protection is maintained.
The extended-life coolant currently approved for use in MACK engines The extended-life coolant currently approved for use in MACK engines
is an ethylene glycol-based coolant that uses Organic Acid Technology is an ethylene glycol-based coolant that uses Organic Acid Technology
(OAT) to protect against corrosion, cavitation erosion and pitting. (OAT) to protect against corrosion, cavitation erosion and pitting.
Organic acid coolants use a combination of carboxylate inhibitors in Organic acid coolants use a combination of carboxylate inhibitors in
place of the traditional SCA package. These inhibitors deplete much place of the traditional SCA package. These inhibitors deplete much
more slowly than the SCA package used in traditional coolants, more slowly than the SCA package used in traditional coolants,
eliminating the need for routine testing of the coolant. Extended-life eliminating the need for routine testing of the coolant. Extended-life
coolants require an annual check for contamination only. coolants require an annual check for contamination only.
Do not use a coolant conditioner containing the Do not use a coolant conditioner containing the
supplemental coolant additive (SCA) package on supplemental coolant additive (SCA) package on
engines in which the cooling system is filled with an engines in which the cooling system is filled with an
extended-life coolant. A coolant filter (part No. extended-life coolant. A coolant filter (part No.
20575545, which is a conditioner canister without the 20575545, which is a conditioner canister without the
SCA package) is available through the MACK Parts SCA package) is available through the MACK Parts
System for MP7 and MP8 engines when extended-life System for MP7 and MP8 engines when extended-life
coolants are used. coolants are used.
94 94
Cooling System Top-Off Cooling System Top-Off

Always use MACK-approved coolants when topping-off the cooling Always use MACK-approved coolants when topping-off the cooling
system. Always top-off with a coolant meeting the same specifications system. Always top-off with a coolant meeting the same specifications
as the coolant already in the system. as the coolant already in the system.
The color of the standard factory-fill coolant is fuchsia The color of the standard factory-fill coolant is fuchsia
(a pinkish/purple shade) or some variation of this color (a pinkish/purple shade) or some variation of this color
depending upon the mix. This standard factory-fill depending upon the mix. This standard factory-fill
coolant is compatible with all other MACK-approved coolant is compatible with all other MACK-approved
traditional ethylene glycol-based coolants. traditional ethylene glycol-based coolants.
The color of Texaco and ROTELLA™ Extended-Life The color of Texaco and ROTELLA™ Extended-Life
coolants is red. The color of traditional propylene coolants is red. The color of traditional propylene
glycol is green. glycol is green.
Fuchsia-colored coolants are NOT extended-life Fuchsia-colored coolants are NOT extended-life
coolants. coolants.
Currently, there are no industry standards for coolant Currently, there are no industry standards for coolant
color, so the color of a coolant is not an accurate color, so the color of a coolant is not an accurate
indication of the type of coolant. Always be sure of the indication of the type of coolant. Always be sure of the
type of coolant used in the cooling system before type of coolant used in the cooling system before
topping-off. topping-off.
TRADITIONAL FULLY-FORMULATED ETHYLENE-GLYCOL AND TRADITIONAL FULLY-FORMULATED ETHYLENE-GLYCOL AND

PROPYLENE-GLYCOL COOLANTS PROPYLENE-GLYCOL COOLANTS
Because of the difference in freeze points between ethylene glycol and Because of the difference in freeze points between ethylene glycol and
propylene glycol, these two types of coolants should not be mixed. propylene glycol, these two types of coolants should not be mixed.
Cooling systems filled with ethylene glycol should be topped-off with Cooling systems filled with ethylene glycol should be topped-off with
ethylene glycol. Cooling systems filled with propylene glycol should be ethylene glycol. Cooling systems filled with propylene glycol should be
topped off with propylene glycol. topped off with propylene glycol.
95 95
EXTENDED-LIFE COOLANTS EXTENDED-LIFE COOLANTS

Although the currently approved extended-life coolants are compatible Although the currently approved extended-life coolants are compatible
with traditional coolants, mixing the two is NOT recommended, as the with traditional coolants, mixing the two is NOT recommended, as the
extended-life capabilities will be compromised. If an extended-life extended-life capabilities will be compromised. If an extended-life
coolant is not available, the cooling system may be topped-off with a coolant is not available, the cooling system may be topped-off with a
traditional antifreeze or quality water. If water is used, freeze protection traditional antifreeze or quality water. If water is used, freeze protection
must be checked and adjusted as soon as possible. If traditional must be checked and adjusted as soon as possible. If traditional
coolant is used, a mixture no greater than 15% traditional coolant to coolant is used, a mixture no greater than 15% traditional coolant to
85% extended-life coolant is permissible. Mixtures containing greater 85% extended-life coolant is permissible. Mixtures containing greater
than 15% traditional coolant will shorten the service interval. In this than 15% traditional coolant will shorten the service interval. In this
case, the cooling system should either be drained, flushed and refilled case, the cooling system should either be drained, flushed and refilled
with fresh extended-life coolant, or the coolant should be treated as a with fresh extended-life coolant, or the coolant should be treated as a
traditional coolant, and traditional coolant maintenance practices traditional coolant, and traditional coolant maintenance practices
(testing nitrite level and adding SCAs as required) should be followed. (testing nitrite level and adding SCAs as required) should be followed.
Coolant Change Intervals Coolant Change Intervals
Coolant is toxic. Keep coolant out of reach of Coolant is toxic. Keep coolant out of reach of
children and pets. children and pets.
Handling and disposing of used coolant is subject Handling and disposing of used coolant is subject
to federal, state and local regulations. Always to federal, state and local regulations. Always
dispose of used coolant in an environmentally safe dispose of used coolant in an environmentally safe
manner, such as at an authorized waste disposal manner, such as at an authorized waste disposal
facility. When in doubt, contact the local facility. When in doubt, contact the local
authorities of the Environmental Protection authorities of the Environmental Protection
Agency (EPA) for guidance as to proper handling Agency (EPA) for guidance as to proper handling
and disposing of used antifreeze. and disposing of used antifreeze.
Avoid prolonged or repeated skin contact with Avoid prolonged or repeated skin contact with
used antifreeze, as such contact can result in skin used antifreeze, as such contact can result in skin
disorders or other bodily injury. Always wash disorders or other bodily injury. Always wash
thoroughly after contact with used antifreeze. thoroughly after contact with used antifreeze.
96 96
TRADITIONAL ETHYLENE-GLYCOL AND PROPYLENE-GLYCOL TRADITIONAL ETHYLENE-GLYCOL AND PROPYLENE-GLYCOL

COOLANTS COOLANTS
The change interval outlined in the following table is for traditional The change interval outlined in the following table is for traditional
ethylene glycol- or propylene glycol-based coolants used in all MACK ethylene glycol- or propylene glycol-based coolants used in all MACK
diesel engines: diesel engines:
All Operating Conditions All Operating Conditions
Kilometers (Miles)* Hours* Months* Kilometers (Miles)* Hours* Months*
500 000 (300,000) 6,000 24 500 000 (300,000) 6,000 24
EXTENDED-LIFE COOLANTS EXTENDED-LIFE COOLANTS

Standard Extended-Life Coolant Change Interval Standard Extended-Life Coolant Change Interval
The change interval outlined in the following table is the standard The change interval outlined in the following table is the standard
change interval for extended-life coolants used in all MACK diesel change interval for extended-life coolants used in all MACK diesel
engines: engines:
All Operating Conditions All Operating Conditions
Kilometers (Miles)* Hours* Months* Kilometers (Miles)* Hours* Months*
1 000 000 (600,000) 12,000 48 1 000 000 (600,000) 12,000 48
Coolant Tests Coolant Tests

The coolant mixture must be properly maintained to provide maximum The coolant mixture must be properly maintained to provide maximum
freeze protection, along with protection against corrosion, cavitation freeze protection, along with protection against corrosion, cavitation
erosion and pitting. The following coolant tests should be performed to erosion and pitting. The following coolant tests should be performed to
ensure that the coolant is providing maximum protection. ensure that the coolant is providing maximum protection.
97 97
FREEZE PROTECTION FREEZE PROTECTION

Coolant freeze protection should be checked twice per year, at each C Coolant freeze protection should be checked twice per year, at each C
and D inspection interval. A mixture between 40%–60% of antifreeze and D inspection interval. A mixture between 40%–60% of antifreeze
and quality water is required. and quality water is required.
Ethylene-glycol or propylene-glycol concentrations Ethylene-glycol or propylene-glycol concentrations

greater than 60% are not recommended. With greater than 60% are not recommended. With
mixtures above 60%, cooling performance degrades. mixtures above 60%, cooling performance degrades.
A refractometer should be used to measure freeze protection. A A refractometer should be used to measure freeze protection. A
refractometer that measures both ethylene-glycol and propylene-glycol refractometer that measures both ethylene-glycol and propylene-glycol
concentrations is available from SPX Kent-Moore. Tool part concentrations is available from SPX Kent-Moore. Tool part
No. J 23688 measures ethylene/propylene-glycol concentration in No. J 23688 measures ethylene/propylene-glycol concentration in
degrees Fahrenheit and tool part No. J 26568 measures ethylene/ degrees Fahrenheit and tool part No. J 26568 measures ethylene/
propylene-glycol concentration in degrees Centigrade. propylene-glycol concentration in degrees Centigrade.
NITRITE LEVEL NITRITE LEVEL

To ensure that the coolant is properly maintained (neither overcharged, To ensure that the coolant is properly maintained (neither overcharged,
nor undercharged), coolant nitrite level must be checked at each oil nor undercharged), coolant nitrite level must be checked at each oil
change interval, prior to changing the coolant conditioner. Test strips change interval, prior to changing the coolant conditioner. Test strips
(part No. 7046-3001M) are available through your MACK dealer. Nitrite (part No. 7046-3001M) are available through your MACK dealer. Nitrite
level should be maintained between 1200 to 4000 ppm. level should be maintained between 1200 to 4000 ppm.
The coolant should be checked with a test strip prior to The coolant should be checked with a test strip prior to
adding antifreeze/quality water solution to the cooling adding antifreeze/quality water solution to the cooling
system and before changing the coolant conditioner. system and before changing the coolant conditioner.
Low concentrations of SCAs will result in cavitation Low concentrations of SCAs will result in cavitation
erosion, pitting and eventual engine failure. High erosion, pitting and eventual engine failure. High
concentrations of SCAs will lead to sludge build-up concentrations of SCAs will lead to sludge build-up
and overheating. and overheating.
98 98
Testing coolant nitrite level is not required with Texaco Testing coolant nitrite level is not required with Texaco
or ROTELLA™ Extended-Life coolants. or ROTELLA™ Extended-Life coolants.
COOLANT pH LEVEL COOLANT pH LEVEL

Coolant pH level is a measure of coolant corrosiveness. For best Coolant pH level is a measure of coolant corrosiveness. For best
results, pH should be maintained between 8.5–10.5 for traditional results, pH should be maintained between 8.5–10.5 for traditional
coolants, and between 7.0–10.0 for extended-life coolants. The coolant coolants, and between 7.0–10.0 for extended-life coolants. The coolant
pH level should be tested at each oil change interval. If coolant pH is pH level should be tested at each oil change interval. If coolant pH is
outside these ranges, the cooling system must be drained and refilled outside these ranges, the cooling system must be drained and refilled
with fresh coolant. Coolant pH above the specified range attacks with fresh coolant. Coolant pH above the specified range attacks
aluminum, copper and other non-ferrous materials in the cooling aluminum, copper and other non-ferrous materials in the cooling
system. Coolants with pH below the specified range may attack ferrous system. Coolants with pH below the specified range may attack ferrous
materials. A coolant pH electronic tester (tool part No. J 41660) is materials. A coolant pH electronic tester (tool part No. J 41660) is
available from SPX Kent-Moore. Additionally, test strip part available from SPX Kent-Moore. Additionally, test strip part
No. 7046-3001M can be used to check coolant pH levels. These strips No. 7046-3001M can be used to check coolant pH levels. These strips
are available from your MACK dealer. are available from your MACK dealer.
ORGANIC ACID CONCENTRATION (EXTENDED-LIFE COOLANTS) ORGANIC ACID CONCENTRATION (EXTENDED-LIFE COOLANTS)
To ensure that the extended-life coolant has not been contaminated To ensure that the extended-life coolant has not been contaminated
with traditional coolant, the coolant mixture should be tested every with traditional coolant, the coolant mixture should be tested every
161 000 km (100,000 miles), 2000 hours or once per year (D 161 000 km (100,000 miles), 2000 hours or once per year (D
inspection interval), whichever occurs first. Test strips are available for inspection interval), whichever occurs first. Test strips are available for
this purpose. The test is a pass/fail type that indicates whether or not this purpose. The test is a pass/fail type that indicates whether or not
the coolant is contaminated. If the test indicates contamination, the the coolant is contaminated. If the test indicates contamination, the
cooling system should be drained, flushed and refilled with fresh cooling system should be drained, flushed and refilled with fresh
extended-life coolant. The test strips can be ordered directly from extended-life coolant. The test strips can be ordered directly from
Chevron Texaco by calling 800-822-5823. Order part No. CPS 900546, Chevron Texaco by calling 800-822-5823. Order part No. CPS 900546,
Extended-Life Coolant dilution test kit. Extended-Life Coolant dilution test kit.
Do not use the nitrite test strips used for testing the Do not use the nitrite test strips used for testing the
nitrite level of traditional coolants to test extended-life nitrite level of traditional coolants to test extended-life
coolants. coolants.
99 99
Coolant Conditioning Coolant Conditioning

The coolant mixture in a wet sleeve diesel engine must be properly The coolant mixture in a wet sleeve diesel engine must be properly
maintained to provide maximum engine block and cylinder sleeve maintained to provide maximum engine block and cylinder sleeve
protection. Engine coolant must contain a proper mixture of quality protection. Engine coolant must contain a proper mixture of quality
water, recommended antifreeze and supplemental coolant additives water, recommended antifreeze and supplemental coolant additives
(SCA) so that maximum freeze and boil point protection, and protection (SCA) so that maximum freeze and boil point protection, and protection
against cavitation erosion is provided. against cavitation erosion is provided.
The spin-on coolant conditioner contains the SCA package inside the The spin-on coolant conditioner contains the SCA package inside the
canister so that a fresh charge of SCA is added to the cooling system canister so that a fresh charge of SCA is added to the cooling system
each time the coolant conditioner is changed. Changing the coolant each time the coolant conditioner is changed. Changing the coolant
conditioner at the recommended maintenance intervals protects conditioner at the recommended maintenance intervals protects
against cavitation erosion damage which can occur to the cylinder against cavitation erosion damage which can occur to the cylinder
block and cylinder sleeves. Always test the coolant nitrite level to block and cylinder sleeves. Always test the coolant nitrite level to
ensure that the coolant is being properly maintained prior to adding ensure that the coolant is being properly maintained prior to adding
antifreeze/quality water to the cooling system, or before changing the antifreeze/quality water to the cooling system, or before changing the
coolant conditioner. coolant conditioner.
A coolant filter (part No. 20575545) that contains a A coolant filter (part No. 20575545) that contains a
filter but no additive package is available for MP7 and filter but no additive package is available for MP7 and
MP8 engines when extended-life coolants are used. MP8 engines when extended-life coolants are used.
Do not use extended-life coolants in engines equipped Do not use extended-life coolants in engines equipped
with a coolant conditioner. Testing coolant nitrite level with a coolant conditioner. Testing coolant nitrite level
is not required with extended-life coolants. is not required with extended-life coolants.
For chassis equipped with Cummins engines, refer to For chassis equipped with Cummins engines, refer to
the Cummins Engine Operation and Maintenance the Cummins Engine Operation and Maintenance
Manual for information concerning coolant Manual for information concerning coolant
conditioning. conditioning.
100 100
COOLANT CONDITIONER CHANGE COOLANT CONDITIONER CHANGE

On MACK MP7 and MP8 engines, the coolant conditioner is located on On MACK MP7 and MP8 engines, the coolant conditioner is located on
the lower right-hand side of the engine. Replacement procedures are the lower right-hand side of the engine. Replacement procedures are
the same for both engines. the same for both engines.
18 18

Figure 18 — Coolant Conditioner Locations Figure 18 — Coolant Conditioner Locations
1. Coolant Conditioner 1. Coolant Conditioner
101 101
Avoid injury. Shut the engine off and allow the Avoid injury. Shut the engine off and allow the
cooling system to cool before removing the cooling system to cool before removing the
pressure cap. Turn the cap to the first stop, but do pressure cap. Turn the cap to the first stop, but do
not depress. Allow any residual pressure to not depress. Allow any residual pressure to
dissipate. After pressure completely dissipates, dissipate. After pressure completely dissipates,
press the cap downward and continue turning to press the cap downward and continue turning to
remove. remove.
The coolant conditioner is replaced as follows: The coolant conditioner is replaced as follows:
1. Rotate the shut-off valve (refer to the following illustration) 1. Rotate the shut-off valve (refer to the following illustration)
counterclockwise. counterclockwise.
19 19

Figure 19 Figure 19
1. Shut-Off Valve 2. Coolant Conditioner 1. Shut-Off Valve 2. Coolant Conditioner
2. Place a suitable container below the coolant filter area to catch 2. Place a suitable container below the coolant filter area to catch
any spilled coolant. any spilled coolant.
3. Using a suitable filter wrench (J 48061, or equivalent), remove the 3. Using a suitable filter wrench (J 48061, or equivalent), remove the
coolant conditioner filter element and discard. coolant conditioner filter element and discard.
102 102
4. Clean the coolant conditioner mounting surface. 4. Clean the coolant conditioner mounting surface.
5. Apply a light film of engine oil to the sealing gasket of the new 5. Apply a light film of engine oil to the sealing gasket of the new
coolant conditioner element. coolant conditioner element.
6. Install the filter element on the coolant conditioner base 6. Install the filter element on the coolant conditioner base
assembly. Tighten the filter element 1/2 to 3/4 turn after the assembly. Tighten the filter element 1/2 to 3/4 turn after the
gasket contacts the base. gasket contacts the base.
7. Rotate the shut-off valve clockwise. 7. Rotate the shut-off valve clockwise.
8. Replenish the cooling system with the proper type and mixture of 8. Replenish the cooling system with the proper type and mixture of
coolant. coolant.
Cooling System Corrosion Cooling System Corrosion

At each A, B, C and D inspection interval, check inside the radiator for At each A, B, C and D inspection interval, check inside the radiator for
signs of corrosion which may be present around the radiator tube ends. signs of corrosion which may be present around the radiator tube ends.
A limited view inside the radiator may be gained by removing the upper A limited view inside the radiator may be gained by removing the upper
radiator hose, after first draining enough coolant from the system to radiator hose, after first draining enough coolant from the system to
bring the level below the top radiator tank. On radiators that have a bring the level below the top radiator tank. On radiators that have a
radiator cap, it is only necessary to remove the cap to look inside the radiator cap, it is only necessary to remove the cap to look inside the
radiator. If corrosion is present, add 3.8 liters (one gallon) of Penray radiator. If corrosion is present, add 3.8 liters (one gallon) of Penray
2001 On-Line Cooling System Cleaner to the cooling system and 2001 On-Line Cooling System Cleaner to the cooling system and
operate the vehicle for approximately 40 000 km (25,000 miles). After operate the vehicle for approximately 40 000 km (25,000 miles). After
40 000 km (25,000 miles), drain and flush the cooling system. Refill the 40 000 km (25,000 miles), drain and flush the cooling system. Refill the
system with fresh coolant, then change the spin-on coolant conditioner. system with fresh coolant, then change the spin-on coolant conditioner.
Fan Arrangement Safety Precautions Fan Arrangement Safety Precautions
Keep clear of fan when engine is running. Fan may Keep clear of fan when engine is running. Fan may
start to rotate at high speed without warning. start to rotate at high speed without warning.
Misuse, misapplication or modification of radiator Misuse, misapplication or modification of radiator

cooling fans can result in serious personal injury cooling fans can result in serious personal injury
and property damage. Basic safety precautions, and property damage. Basic safety precautions,
including the following, should always be including the following, should always be
followed. followed.
103 103
1. DO NOT operate the engine with a defective fan drive, or with a 1. DO NOT operate the engine with a defective fan drive, or with a
fan which has been bent, mutilated, modified or damaged. fan which has been bent, mutilated, modified or damaged.
Continued operation could result in serious failure resulting in Continued operation could result in serious failure resulting in
injury or property damage. injury or property damage.
2. If there is evidence of fan drive malfunction or exterior damage to 2. If there is evidence of fan drive malfunction or exterior damage to
the drive or fan, remove and replace both items. Field repair the drive or fan, remove and replace both items. Field repair
involving disassembly of an air sensing viscous fan drive or an involving disassembly of an air sensing viscous fan drive or an
electronically modulated fan drive can be dangerous and is not electronically modulated fan drive can be dangerous and is not
recommended. Contact your nearest MACK distributor. recommended. Contact your nearest MACK distributor.
3. Replace the fan if there appears to be any indication of damage 3. Replace the fan if there appears to be any indication of damage
to the fan. to the fan.
4. Never attempt to restrict fan blade rotation during engine 4. Never attempt to restrict fan blade rotation during engine
operation. Serious personal injury, property damage or damage operation. Serious personal injury, property damage or damage
to the fan drive could result. to the fan drive could result.
5. DO NOT operate the engine if the fan strikes against any engine 5. DO NOT operate the engine if the fan strikes against any engine
component while in operation. component while in operation.
6. Never operate an air sensing viscous fan with a fully closed 6. Never operate an air sensing viscous fan with a fully closed
winterfront. The winterfront center panel must be kept fully open. winterfront. The winterfront center panel must be kept fully open.
Do not use cardboard or other similar improvised restrictions. Do not use cardboard or other similar improvised restrictions.
7. Have the fan and fan drive inspected by a qualified mechanic if it 7. Have the fan and fan drive inspected by a qualified mechanic if it
has been exposed to excessively high temperatures (about has been exposed to excessively high temperatures (about
121°C [250°F]), and it contains any plastic or rubber components. 121°C [250°F]), and it contains any plastic or rubber components.
8. DO NOT rebalance the fan. If balancing is necessary, contact 8. DO NOT rebalance the fan. If balancing is necessary, contact
your nearest MACK dealer. your nearest MACK dealer.
9. Perform all required maintenance on the fan drive assembly. 9. Perform all required maintenance on the fan drive assembly.
10. Ensure that all bolts attaching the fan to the drive are tightened to 10. Ensure that all bolts attaching the fan to the drive are tightened to
the specified torque. the specified torque.
11. Install the fan only on an engine that has been approved for such 11. Install the fan only on an engine that has been approved for such
a fan. (Check the engine manufacturer’s part list.) Likewise, install a fan. (Check the engine manufacturer’s part list.) Likewise, install
a subassembly to which the fan is attached only if approved or a subassembly to which the fan is attached only if approved or
specified for use on the engine. specified for use on the engine.
12. DO NOT modify or substitute any parts of the engine unless in 12. DO NOT modify or substitute any parts of the engine unless in
accordance with the engine manufacturer’s instructions. Take accordance with the engine manufacturer’s instructions. Take
special care not to make modifications that increase the operating special care not to make modifications that increase the operating
speed of the fan. speed of the fan.
104 104
COLD WEATHER OPERATION COLD WEATHER OPERATION

Cold weather operations place added demands on a diesel engine. Cold weather operations place added demands on a diesel engine.
Heavy-duty diesel engines are designed to operate at optimum Heavy-duty diesel engines are designed to operate at optimum
efficiency when running loaded at, or very near, normal operating efficiency when running loaded at, or very near, normal operating
temperature where efficient combustion takes place. When operating temperature where efficient combustion takes place. When operating
unloaded, lightly loaded (stop-and-go operations, PTO operations or unloaded, lightly loaded (stop-and-go operations, PTO operations or
periods of extended engine idling), or in cold weather conditions, periods of extended engine idling), or in cold weather conditions,
normal operating temperature may not be achieved or maintained. The normal operating temperature may not be achieved or maintained. The
incomplete combustion of fuel will result in oil dilution, “slobbering” from incomplete combustion of fuel will result in oil dilution, “slobbering” from
the exhaust, carbon and/or varnish build-up on the valves and oil the exhaust, carbon and/or varnish build-up on the valves and oil
thickening and sludge formation may result. In severe instances, heavy thickening and sludge formation may result. In severe instances, heavy
deposits of varnish can cause sticking valves which can result in bent deposits of varnish can cause sticking valves which can result in bent
valves, bent push rods or similar types of valve train component failure. valves, bent push rods or similar types of valve train component failure.
At cold weather start-up, and during periods of extended idling, a fast At cold weather start-up, and during periods of extended idling, a fast
idle speed of 1200 rpm must be used to provide and maintain a idle speed of 1200 rpm must be used to provide and maintain a
minimum coolant temperature of 77°C (170°F). In addition, the cold minimum coolant temperature of 77°C (170°F). In addition, the cold
weather accessories described in this manual may be needed based weather accessories described in this manual may be needed based
upon the anticipated ambient temperatures. upon the anticipated ambient temperatures.
If the vehicle is kept outside during cold temperatures, If the vehicle is kept outside during cold temperatures,
and cold weather start-up and warm-up to normal and cold weather start-up and warm-up to normal
operating temperature is difficult, a cylinder block operating temperature is difficult, a cylinder block
heater is recommended. heater is recommended.
During cold weather operations, it is important that coolant system During cold weather operations, it is important that coolant system
maintenance be performed regularly, and that thermostat operation be maintenance be performed regularly, and that thermostat operation be
checked to make sure it closes fully, does not allow any leakage and checked to make sure it closes fully, does not allow any leakage and
does not open too soon. The thermostat seal should also be checked does not open too soon. The thermostat seal should also be checked
for leakage. Coolant leaking past the thermostat will cause for leakage. Coolant leaking past the thermostat will cause
over-cooling. over-cooling.
105 105
Ether and Cold Weather Starting Ether and Cold Weather Starting
Use of ether or other similar starting aids in the MACK MP series of Use of ether or other similar starting aids in the MACK MP series of
engines is strictly prohibited. This applies to all MACK MP engines engines is strictly prohibited. This applies to all MACK MP engines
whether or not the engine is equipped with the cold weather electric whether or not the engine is equipped with the cold weather electric
pre-heater option. pre-heater option.
For cold weather starting, the only acceptable starting aid is the electric For cold weather starting, the only acceptable starting aid is the electric
pre-heater option. This option is a factory-installed electric grid element pre-heater option. This option is a factory-installed electric grid element
which is located inside the intake manifold and heats the intake air at which is located inside the intake manifold and heats the intake air at
cold start-up. cold start-up.
Spraying ether or similar starting aids into the air Spraying ether or similar starting aids into the air
cleaner of an engine equipped with an electric pre- cleaner of an engine equipped with an electric pre-
heater could result in a fire or explosion, causing heater could result in a fire or explosion, causing
severe personal injury or death. severe personal injury or death.
Use of ether or similar starting aids in MACK US07 Use of ether or similar starting aids in MACK US07
emission compliant and later engines which are not emission compliant and later engines which are not
equipped with the cold weather pre-heater option is equipped with the cold weather pre-heater option is
also prohibited. also prohibited.
106 106
Cold Weather Accessories Cold Weather Accessories

Cold weather operations place an added demand on a diesel engine. Cold weather operations place an added demand on a diesel engine.
The following chart outlines the various accessories available that are The following chart outlines the various accessories available that are
designed to maximize engine reliability when operating in cold weather. designed to maximize engine reliability when operating in cold weather.
Component CXU CHU GU7 GU8 MRU LEU Component CXU CHU GU7 GU8 MRU LEU
Dual-Inlet Air X X X X NA NA Dual-Inlet Air X X X X NA NA

Cleaner Cleaner
Inside/Outside Air X X X X NA NA Inside/Outside Air X X X X NA NA
Engine Heater X X X X X X Engine Heater X X X X X X
Fuel Heater X X X X X X Fuel Heater X X X X X X
WINTERFRONTS WINTERFRONTS
Winterfronts are NOT recommended, but may be used Winterfronts are NOT recommended, but may be used
during very cold weather when sustained during very cold weather when sustained
temperatures are below −25°C (−13°F). temperatures are below −25°C (−13°F).
If a winterfront must be used, use only a winterfront If a winterfront must be used, use only a winterfront
designed for the specific chassis. Restricted airflow designed for the specific chassis. Restricted airflow
through the charge air cooler can cause higher through the charge air cooler can cause higher
exhaust temperatures, power loss, excessive fan exhaust temperatures, power loss, excessive fan
usage, reduced fuel economy and possible engine usage, reduced fuel economy and possible engine
damage. The use of any other type of device, such as damage. The use of any other type of device, such as
a radiator cover, cardboard or similar material, is not a radiator cover, cardboard or similar material, is not
approved by Mack Trucks, Inc. approved by Mack Trucks, Inc.
If a winterfront is used, a MACK-approved pyrometer MUST also be If a winterfront is used, a MACK-approved pyrometer MUST also be
installed and closely monitored while the engine is in operation. DO installed and closely monitored while the engine is in operation. DO
NOT exceed the temperature limit shown on the pyrometer. If exhaust NOT exceed the temperature limit shown on the pyrometer. If exhaust
temperature becomes too high, open the winterfront, downshift or temperature becomes too high, open the winterfront, downshift or
reduce engine power. reduce engine power.
107 107
ENGINE ENCLOSURE/BELLY TARP ENGINE ENCLOSURE/BELLY TARP

A belly tarp is a canvas enclosure that is installed along the bottom of A belly tarp is a canvas enclosure that is installed along the bottom of
the engine and helps retain heat within the engine compartment. Belly the engine and helps retain heat within the engine compartment. Belly
tarps are generally used at colder ambient temperatures when a tarps are generally used at colder ambient temperatures when a
winterfront alone is not sufficient and may be fabricated from a piece of winterfront alone is not sufficient and may be fabricated from a piece of
canvas of sufficient size to completely cover the underside of the canvas of sufficient size to completely cover the underside of the
engine compartment. The canvas tarp is then secured to the chassis engine compartment. The canvas tarp is then secured to the chassis
with rubber straps, or “Bungie Cords.” Make sure that the tarp does not with rubber straps, or “Bungie Cords.” Make sure that the tarp does not
obstruct the engine breather, interfere with any linkages or contact any obstruct the engine breather, interfere with any linkages or contact any
part of the exhaust system. part of the exhaust system.
DUAL-INLET AIR CLEANER DUAL-INLET AIR CLEANER

A dual-inlet air cleaner (part No. 2MD4138M) for CXU, CHU, GU7 and A dual-inlet air cleaner (part No. 2MD4138M) for CXU, CHU, GU7 and
GU8 model vehicles is available from your local MACK dealer. This GU8 model vehicles is available from your local MACK dealer. This
type of air cleaner has a second air inlet located above the type of air cleaner has a second air inlet located above the
turbocharger/exhaust pipe to provide a means of heating the intake air turbocharger/exhaust pipe to provide a means of heating the intake air
during cold weather operations. The air inlet is covered with a manually during cold weather operations. The air inlet is covered with a manually
operated sliding door. When operating in cold weather, loosen the four operated sliding door. When operating in cold weather, loosen the four
wing nuts that secure the door, then slide the door to the opened wing nuts that secure the door, then slide the door to the opened
position. Secure the sliding door in the opened position by tightening position. Secure the sliding door in the opened position by tightening
the wing nuts. Refer to the chart at the end of this section for the the wing nuts. Refer to the chart at the end of this section for the
suggested temperature ranges as to when the air cleaner sliding door suggested temperature ranges as to when the air cleaner sliding door
should be closed, and when it should be opened. should be closed, and when it should be opened.
20 20
Figure 20 — Dual-Inlet Air Cleaner Figure 20 — Dual-Inlet Air Cleaner
108 108
COLD-WEATHER ACCESSORY USAGE COLD-WEATHER ACCESSORY USAGE

Refer to the following chart for the suggested temperature ranges when Refer to the following chart for the suggested temperature ranges when
the various cold-weather accessories should be used. the various cold-weather accessories should be used.
Expected Expected
Sustained Sustained
Coldest Ambient Inside/Outside Coldest Ambient Inside/Outside
Temperature Air Dual-Inlet Temperature Air Dual-Inlet
Range Winterfront Belly Tarp Air Cleaner Range Winterfront Belly Tarp Air Cleaner
5°C (40°F) Prohibited 5°C (40°F) Prohibited

Available Available
0°C (32°F) 0°C (32°F)
−5°C (23°F) Prohibited Available −5°C (23°F) Prohibited Available

Suggested Suggested
(Opened) (Opened)
−10°C (14°F) −10°C (14°F)
−15°C (5°F) −15°C (5°F)

Suggested Suggested
−20°C (−4°F) −20°C (−4°F)
−25°C (−13°F) Recommended −25°C (−13°F) Recommended

−30°C (−22°F) Can Be Used (Opened) −30°C (−22°F) Can Be Used (Opened)
Recommended Recommended
−35°C (−30°F) −35°C (−30°F)
−40°C (−40°F) −40°C (−40°F)
109 109
HOSE CLAMP TORQUES HOSE CLAMP TORQUES
HOSE CLAMP TORQUES HOSE CLAMP TORQUES
System N•m (Lb-in) System N•m (Lb-in)

Coolant System 3.1 (27.5) Coolant System 3.1 (27.5)
Oil Return System 3.1 (27.5) Oil Return System 3.1 (27.5)
EGR System EGR System
앫 Hi-torque V-band clamps 12 (110) 앫 Hi-torque V-band clamps 12 (110)
Air Inlet System: Air Inlet System:
Pressurized hoses* Pressurized hoses*
앫 Spring-loaded T-bolt hose clamps 8.5 (75) 앫 Spring-loaded T-bolt hose clamps 8.5 (75)
앫 Hi-torque V-band clamps 8.0 (70) 앫 Hi-torque V-band clamps 8.0 (70)
Non-pressurized hoses** Non-pressurized hoses**
앫 Standard hose clamps 4.2 (37.5) 앫 Standard hose clamps 4.2 (37.5)
앫 Spring-loaded T-bolt hose clamps 5.7 (50) 앫 Spring-loaded T-bolt hose clamps 5.7 (50)
앫 High-torque heavy-duty worm clamps 9 (80) 앫 High-torque heavy-duty worm clamps 9 (80)
* Includes all clamps installed between the turbocharger outlet and the inlet * Includes all clamps installed between the turbocharger outlet and the inlet
manifold, charge air cooler and inlet manifold connecting hose. manifold, charge air cooler and inlet manifold connecting hose.
** Includes all hoses between the air cleaner and the turbocharger inlet. ** Includes all hoses between the air cleaner and the turbocharger inlet.
21 21

Figure 21 — Hose Clamp Types Figure 21 — Hose Clamp Types
110 110
AIR CONDITIONER MAINTENANCE AIR CONDITIONER MAINTENANCE

Periodic Inspections Periodic Inspections
To ensure proper air conditioner operation, the following procedures To ensure proper air conditioner operation, the following procedures
should be performed at each A, B, C and D inspection interval. should be performed at each A, B, C and D inspection interval.
1. Inspect evaporator core (and heater core if a combination unit) for 1. Inspect evaporator core (and heater core if a combination unit) for
obstructions, and use compressed air to remove any debris that obstructions, and use compressed air to remove any debris that
may be found. may be found.
Use care to prevent damaging the blower wheel Use care to prevent damaging the blower wheel
blades. blades.
2. Inspect condenser unit and remove any debris with compressed 2. Inspect condenser unit and remove any debris with compressed
air. Tighten any loose fasteners. air. Tighten any loose fasteners.
3. Inspect the compressor. Check for loose or broken wires, and 3. Inspect the compressor. Check for loose or broken wires, and
tighten nuts and bolts on compressor mounting bracket and tighten nuts and bolts on compressor mounting bracket and
clutch. clutch.
4. Check compressor drive belt tension and adjust, if necessary. 4. Check compressor drive belt tension and adjust, if necessary.
(Refer to “DRIVE BELTS” on page 79.) (Refer to “DRIVE BELTS” on page 79.)
5. Inspect refrigerant hoses for abrasion or wear, and check all 5. Inspect refrigerant hoses for abrasion or wear, and check all
connections for leaks. connections for leaks.
6. Check condensation drain hose leading from the evaporator and 6. Check condensation drain hose leading from the evaporator and
make sure it is not kinked or otherwise restricted. make sure it is not kinked or otherwise restricted.
7. Start the engine, turn the air conditioner ON and listen for any 7. Start the engine, turn the air conditioner ON and listen for any
unusual noise coming from the compressor. The compressor unusual noise coming from the compressor. The compressor
clutch should rotate when the thermostatic switch is turned ON, clutch should rotate when the thermostatic switch is turned ON,
and should not rotate when the switch is turned OFF. and should not rotate when the switch is turned OFF.
8. Check the receiver/dryer service indicator. The normal color of 8. Check the receiver/dryer service indicator. The normal color of
the service indicator is blue. Replace the receiver/dryer when the the service indicator is blue. Replace the receiver/dryer when the
service indicator color changes to pink. Refer to the service service indicator color changes to pink. Refer to the service
instruction label found on the receiver/dryer. instruction label found on the receiver/dryer.
9. Determine if system is fully charged. Refer to Air Conditioning 9. Determine if system is fully charged. Refer to Air Conditioning
Service literature for proper procedures. Service literature for proper procedures.
111 111
10. Check for proper blower speed control. 10. Check for proper blower speed control.
11. Determine satisfactory air conditioner performance by measuring 11. Determine satisfactory air conditioner performance by measuring
the air temperature at the vent nearest to the evaporator. the air temperature at the vent nearest to the evaporator.
Acceptable air temperature at this location is a thermometer Acceptable air temperature at this location is a thermometer
reading below 4.4°C (40°F) with ambient air temperature around reading below 4.4°C (40°F) with ambient air temperature around
21°C (70°F). 21°C (70°F).
For specific information concerning air conditioning For specific information concerning air conditioning
maintenance and service procedures, refer to the maintenance and service procedures, refer to the
manufacturer’s service manual. manufacturer’s service manual.
MACK model chassis are factory-filled with the MACK model chassis are factory-filled with the
environmentally safe refrigerant R134a. This environmentally safe refrigerant R134a. This
refrigerant is not a direct replacement for R12 refrigerant is not a direct replacement for R12
refrigerant and must only be used in systems designed refrigerant and must only be used in systems designed
for its use. DO NOT use R134a in a system already for its use. DO NOT use R134a in a system already
charged with, or designed to use, R12. Conversely, charged with, or designed to use, R12. Conversely,
DO NOT use R12 in a system already charged with, or DO NOT use R12 in a system already charged with, or
designed to use, R134a. designed to use, R134a.
112 112
AIR CLEANER MAINTENANCE AIR CLEANER MAINTENANCE

The air cleaner prevents dust, dirt and other harmful contaminants The air cleaner prevents dust, dirt and other harmful contaminants
from entering the engine through the air intake system. Maximum from entering the engine through the air intake system. Maximum
engine protection can only be achieved through regularly scheduled engine protection can only be achieved through regularly scheduled
maintenance practices that include periodic air intake system maintenance practices that include periodic air intake system
inspections and air filter element changes. inspections and air filter element changes.
The most efficient method of determining air filter element change The most efficient method of determining air filter element change
intervals is by regularly checking the air filter restriction gauge, which intervals is by regularly checking the air filter restriction gauge, which
may either be mounted directly to the air cleaner canister, on the air may either be mounted directly to the air cleaner canister, on the air
cleaner outlet tube or inside the cab. The restriction gauge measures cleaner outlet tube or inside the cab. The restriction gauge measures
the amount of restriction in the air filter element. Some chassis may the amount of restriction in the air filter element. Some chassis may
have a dash-mounted dial-type restriction gauge which measures filter have a dash-mounted dial-type restriction gauge which measures filter
restriction in mm/inches of water. restriction in mm/inches of water.
Change the air filter element in accordance with the procedures as Change the air filter element in accordance with the procedures as
outlined, when the restriction gauge red signal locks in full view, or the outlined, when the restriction gauge red signal locks in full view, or the
dash-mounted gauge indicates inlet restriction as follows: dash-mounted gauge indicates inlet restriction as follows:
DASH-MOUNTED GAUGE INLET RESTRICTION INDICATION DASH-MOUNTED GAUGE INLET RESTRICTION INDICATION
Engine Millimeters Water/kPa Engine Millimeters Water/kPa
MP7 and MP8 510 mm (20″)/5 kPa MP7 and MP8 510 mm (20″)/5 kPa
113 113
22 22
Figure 22 — Air Filter Restriction Gauge Figure 22 — Air Filter Restriction Gauge
Damage to the air filter element, such as holes in the filter medium, will Damage to the air filter element, such as holes in the filter medium, will
give an inaccurate restriction reading. Therefore, even if maximum give an inaccurate restriction reading. Therefore, even if maximum
restriction is not indicated, the air filter element should be changed restriction is not indicated, the air filter element should be changed
yearly or at 160 000-km (100,000-mile) intervals, whichever comes yearly or at 160 000-km (100,000-mile) intervals, whichever comes
first. first.
When replacing the air filter element, or whenever the air inlet system When replacing the air filter element, or whenever the air inlet system
has been disassembled, inspect the inlet air ducts between the air has been disassembled, inspect the inlet air ducts between the air
cleaner canister outlet and the turbocharger inlet as follows: cleaner canister outlet and the turbocharger inlet as follows:
앫 Inspect the rubber elbows for cracks, splitting and/or holes. 앫 Inspect the rubber elbows for cracks, splitting and/or holes.
Rubber components must be flexible so that they conform to the Rubber components must be flexible so that they conform to the
plastic ducts and ensure a tight seal. plastic ducts and ensure a tight seal.
앫 Inspect plastic ducts for cracks and/or holes. 앫 Inspect plastic ducts for cracks and/or holes.
앫 Ensure that all hose clamps are properly installed and tightened 앫 Ensure that all hose clamps are properly installed and tightened
to specifications. Refer to “HOSE CLAMP TORQUES” on page to specifications. Refer to “HOSE CLAMP TORQUES” on page
110. 110.
앫 Make sure the plastic ducts do not rub against any components 앫 Make sure the plastic ducts do not rub against any components
such as air conditioning hoses, wire harnesses, etc. such as air conditioning hoses, wire harnesses, etc.
To properly install a new filter element: To properly install a new filter element:
1. Wipe the air cleaner housing clean. 1. Wipe the air cleaner housing clean.
2. Remove the filter element(s). 2. Remove the filter element(s).
114 114
3. Inspect sealing areas for “dirt tracks” which would indicate that 3. Inspect sealing areas for “dirt tracks” which would indicate that
dust has leaked past the seal. If dirt tracks are found, the cause dust has leaked past the seal. If dirt tracks are found, the cause
must be determined and corrected. must be determined and corrected.
4. Thoroughly clean the inside of the air cleaner canister with a 4. Thoroughly clean the inside of the air cleaner canister with a
damp cloth or vacuum cleaner. damp cloth or vacuum cleaner.
5. If equipped with a metal canister, inspect inside the canister for 5. If equipped with a metal canister, inspect inside the canister for
rust. If rust is present: rust. If rust is present:
a. Remove the air cleaner canister from the chassis. a. Remove the air cleaner canister from the chassis.
b. Remove all loose rust with a wire brush or a coarse b. Remove all loose rust with a wire brush or a coarse
Scotch Brite pad. Scotch Brite pad.
c. Sand with 180–240 grit wet or dry sand paper. c. Sand with 180–240 grit wet or dry sand paper.
d. Thoroughly wash the area with PPG DX-440, DX-436, d. Thoroughly wash the area with PPG DX-440, DX-436,
DX-437 or equivalent, wax and grease remover and wipe DX-437 or equivalent, wax and grease remover and wipe
dry. dry.
e. Prime immediately with PPG DEP-351 epoxy primer. e. Prime immediately with PPG DEP-351 epoxy primer.
f. Reinstall the air cleaner canister. f. Reinstall the air cleaner canister.
6. Inspect the sealing areas of the housing for damage. Repair or 6. Inspect the sealing areas of the housing for damage. Repair or
replace as necessary. replace as necessary.
7. Use MACK-approved replacement elements and gaskets. Make 7. Use MACK-approved replacement elements and gaskets. Make
sure the new elements and gaskets are not damaged. Be sure to sure the new elements and gaskets are not damaged. Be sure to
use new gaskets each time the element is changed. Install the use new gaskets each time the element is changed. Install the
cover and, depending upon cover configuration, tighten as cover and, depending upon cover configuration, tighten as
follows: follows:
앫 Air cleaner with large wing nut in center of cover — 앫 Air cleaner with large wing nut in center of cover —
hand-tighten wing nut. hand-tighten wing nut.
앫 Air cleaner with three thumb screws around outer edge of 앫 Air cleaner with three thumb screws around outer edge of
cover — hand-tighten thumb screws. cover — hand-tighten thumb screws.
앫 Air cleaner with retaining nuts around outer edge of cover — 앫 Air cleaner with retaining nuts around outer edge of cover —
tighten retaining nuts between 11–14 N•m (8–10 lb-ft). tighten retaining nuts between 11–14 N•m (8–10 lb-ft).
115 115
DO NOT attempt to clean the air filter element with DO NOT attempt to clean the air filter element with
compressed air, as this could damage the filter compressed air, as this could damage the filter
medium and possibly result in severe engine damage. medium and possibly result in severe engine damage.
23 23
Figure 23 — Replacement Parts and Filters Figure 23 — Replacement Parts and Filters
116 116
TURBOCHARGERS TURBOCHARGERS
Turbochargers are lubricated by oil from the engine. Scheduled engine Turbochargers are lubricated by oil from the engine. Scheduled engine
oil changes take care of any periodic service requirements. oil changes take care of any periodic service requirements.
Because a turbocharger operates at such high speeds, lubrication at Because a turbocharger operates at such high speeds, lubrication at
start-up and shutdown is of primary importance. start-up and shutdown is of primary importance.
When the engine is started, idle for three minutes to allow the oil When the engine is started, idle for three minutes to allow the oil
pressure to build. Accelerating the engine to top rpm immediately after pressure to build. Accelerating the engine to top rpm immediately after
starting may damage the turbocharger. starting may damage the turbocharger.
Likewise, when preparing to shut down, idle the engine for three Likewise, when preparing to shut down, idle the engine for three
minutes to ensure that the turbocharger is rotating slowly. This idling minutes to ensure that the turbocharger is rotating slowly. This idling
period dissipates heat and prevents possible turbocharger damage. period dissipates heat and prevents possible turbocharger damage.
At each 240 000 km/150,000 miles or 4500-hour interval (whichever At each 240 000 km/150,000 miles or 4500-hour interval (whichever
occurs first), thoroughly clean the outside of the turbocharger. Pay occurs first), thoroughly clean the outside of the turbocharger. Pay
particular attention to the areas of the large intake and exhaust pipe particular attention to the areas of the large intake and exhaust pipe
connections. Remove the air intake and exhaust pipes from the connections. Remove the air intake and exhaust pipes from the
turbocharger. turbocharger.
Prior to inspecting the turbocharger, disconnect the Prior to inspecting the turbocharger, disconnect the
batteries by disconnecting the negative cables first, batteries by disconnecting the negative cables first,
then the positive cables. Do this to prevent the engine then the positive cables. Do this to prevent the engine
from being started while inspecting the turbocharger. from being started while inspecting the turbocharger.
DO NOT allow any debris or foreign material to enter DO NOT allow any debris or foreign material to enter
the turbocharger openings or connecting pipes. the turbocharger openings or connecting pipes.
Inspect both housings and the wheel blades for signs of excessive dirt Inspect both housings and the wheel blades for signs of excessive dirt
buildup or oil leakage from the bearing housing. Turn the wheel blades buildup or oil leakage from the bearing housing. Turn the wheel blades
with the fingers while pushing in various directions to check for wheel- with the fingers while pushing in various directions to check for wheel-
to-housing rub. If rubbing or a severe buildup of dirt exists, replace the to-housing rub. If rubbing or a severe buildup of dirt exists, replace the
turbocharger. turbocharger.
117 117
After completing the inspection, reinstall the air intake and exhaust After completing the inspection, reinstall the air intake and exhaust
pipes. pipes.
The engine turbocharger operates at very high speed, temperatures The engine turbocharger operates at very high speed, temperatures
and pressure. Turbo bearing lubrication is critical, particularly for a and pressure. Turbo bearing lubrication is critical, particularly for a
newly installed turbo or one which has not been operated for a period newly installed turbo or one which has not been operated for a period
of time and all oil has drained from the bearing and shaft surfaces. To of time and all oil has drained from the bearing and shaft surfaces. To
avoid turbocharger bearing failure, the following instructions are avoid turbocharger bearing failure, the following instructions are
recommended: recommended:
앫 Start the engine at least every 30 days to ensure turbo bearing 앫 Start the engine at least every 30 days to ensure turbo bearing
lubrication. Operate engine at low idle for at least three minutes lubrication. Operate engine at low idle for at least three minutes
before increasing RPM or driving the vehicle. before increasing RPM or driving the vehicle.
앫 If the engine has not been run for more than 30 days, turbo 앫 If the engine has not been run for more than 30 days, turbo
pre-lube procedure is necessary: pre-lube procedure is necessary:
1. Remove turbo air intake duct and oil line connection at 1. Remove turbo air intake duct and oil line connection at
turbo. turbo.
2. Fill oil inlet fitting to overflow with clean engine oil. 2. Fill oil inlet fitting to overflow with clean engine oil.
3. Using fingers at compressor wheel, carefully spin and 3. Using fingers at compressor wheel, carefully spin and
wiggle the turbo shaft to distribute the oil over all bearing wiggle the turbo shaft to distribute the oil over all bearing
surfaces. surfaces.
4. Reconnect air intake duct and again fill turbo oil port to 4. Reconnect air intake duct and again fill turbo oil port to
overflow, connect oil line and start engine. overflow, connect oil line and start engine.
5. Operate engine at low idle for at least three minutes before 5. Operate engine at low idle for at least three minutes before
increasing RPM or driving the vehicle. increasing RPM or driving the vehicle.
118 118
DIESEL PARTICULATE FILTER (DPF) DIESEL PARTICULATE FILTER (DPF)

Ash Cleaning Interval Ash Cleaning Interval
For both catalyzed and non-catalyzed DPF systems, ash must be For both catalyzed and non-catalyzed DPF systems, ash must be
cleaned from the filter by using an approved cleaning system at each cleaned from the filter by using an approved cleaning system at each
400 000 km/250,000 mile or 4,500 hours, whichever occurs first. 400 000 km/250,000 mile or 4,500 hours, whichever occurs first.
Aftertreatment Hydrocarbon Injector Aftertreatment Hydrocarbon Injector

For catalyzed DPF systems, the Aftertreatment Hydrocarbon Injector For catalyzed DPF systems, the Aftertreatment Hydrocarbon Injector
(AHI) must be removed and cleaned with a suitable solvent at each (AHI) must be removed and cleaned with a suitable solvent at each
240 000 km/150,000 mile or 4,500 hour interval. For instructions on 240 000 km/150,000 mile or 4,500 hour interval. For instructions on
removing, cleaning and reinstalling the AHI, refer to the applicable removing, cleaning and reinstalling the AHI, refer to the applicable
service manual. service manual.
24 24

Figure 24 — Aftertreatment Hydrocarbon Injector (AHI) Figure 24 — Aftertreatment Hydrocarbon Injector (AHI)
119 119
On the non-catalyzed DPF system, clean or replace (as required) the On the non-catalyzed DPF system, clean or replace (as required) the
ignition electrodes and the injection nozzle at each 161 000 km/ ignition electrodes and the injection nozzle at each 161 000 km/
100,000 mile or 2,400 hour interval, whichever occurs first. The 100,000 mile or 2,400 hour interval, whichever occurs first. The
electrodes and nozzle are located at the bottom of the DPF unit. electrodes and nozzle are located at the bottom of the DPF unit.
25 25

Figure 25 — Ignition Electrodes and Injection Nozzle — Non-Catalyzed Figure 25 — Ignition Electrodes and Injection Nozzle — Non-Catalyzed
DPF System DPF System
1. Ignition Electrode 3. Ignition Cables 1. Ignition Electrode 3. Ignition Cables

2. Injection Nozzle 4. Ignition Coil 2. Injection Nozzle 4. Ignition Coil
Allow the exhaust system to cool before Allow the exhaust system to cool before
performing any maintenance on the DPF system. performing any maintenance on the DPF system.
120 120
DO NOT use compressed air to remove ash from the DO NOT use compressed air to remove ash from the
filter or housing. Ash removal must be performed per filter or housing. Ash removal must be performed per
the applicable service literature. Dispose of the ash in the applicable service literature. Dispose of the ash in
accordance with all state and local regulations. accordance with all state and local regulations.
Failure to use the mandatory Ultra Low Sulfur Diesel Failure to use the mandatory Ultra Low Sulfur Diesel
(ULSD) fuel and the ’07 Low Ash Diesel Engine oil will (ULSD) fuel and the ’07 Low Ash Diesel Engine oil will
result in major damage to and failure of the DPF unit, result in major damage to and failure of the DPF unit,
very poor engine performance, and the engine may very poor engine performance, and the engine may
not run at all. If premature failure of the DPF is found not run at all. If premature failure of the DPF is found
to have resulted from failure to use the mandatory to have resulted from failure to use the mandatory
ULSD fuel and/or ’07 Low Ash Oil, warranty will be ULSD fuel and/or ’07 Low Ash Oil, warranty will be
denied. denied.
Diesel Particulate Filters and their components cannot Diesel Particulate Filters and their components cannot
be moved or altered from the OEM installation in any be moved or altered from the OEM installation in any
fashion. fashion.
앫 Moving or altering the DPF unit or its 앫 Moving or altering the DPF unit or its
components will result in emission system components will result in emission system
malfunction or failure. malfunction or failure.
앫 Altering the emissions control system is 앫 Altering the emissions control system is
prohibited by the Environmental Protection prohibited by the Environmental Protection
Agency (EPA). Agency (EPA).
앫 Dealers and/or body builders are NOT 앫 Dealers and/or body builders are NOT
authorized to alter or modify the emissions authorized to alter or modify the emissions
control system or any of the emissions related control system or any of the emissions related
앫 Turbo-unloaders are NOT to be used on chassis 앫 Turbo-unloaders are NOT to be used on chassis
equipped with diesel particulate filters. equipped with diesel particulate filters.
121 121
CMCAC CMCAC
CMCAC CMCAC
The Chassis-Mounted Charge Air Cooling (CMCAC) system requires The Chassis-Mounted Charge Air Cooling (CMCAC) system requires
the following maintenance procedures at the recommended intervals. the following maintenance procedures at the recommended intervals.
Daily Maintenance Daily Maintenance

Using a firm bristle brush and soapy water, remove all bugs, leaves and Using a firm bristle brush and soapy water, remove all bugs, leaves and
other debris from the frontal area. other debris from the frontal area.
26 26
$ & !" $ &!" $ & !" $ &!"
" #!! ! " #!! !
#"! ! %" #"! ! %"
!""! ! !" !""! ! !"
" #!!" ! #! !" " #!!" ! #! !"
( )'
( #! " $ ! ( )'
( #! " $ !
!%"% !! " !%"% !! "
()' ( ! " ()' ( ! "
%! %!
Figure 26 — Charge Air Cooler Maintenance Figure 26 — Charge Air Cooler Maintenance
Clean any debris that may accumulate between the Clean any debris that may accumulate between the
radiator core, charge air cooler core and the air radiator core, charge air cooler core and the air
conditioner condenser core. conditioner condenser core.
122 122
CMCAC CMCAC
27 27
!
!

!

!

#" #"

Figure 27 — Charge Air Cooler Maintenance Figure 27 — Charge Air Cooler Maintenance
On CX models, checking torque of the radiator-to- On CX models, checking torque of the radiator-to-
charge air cooler mounting bolts is not necessary. charge air cooler mounting bolts is not necessary.
123 123
FUEL SYSTEM FUEL SYSTEM
General field practice is to prime the fuel filters before General field practice is to prime the fuel filters before
installation. This practice can allow dirt to enter the installation. This practice can allow dirt to enter the
outlet port of the filter if caution is not used. Use outlet port of the filter if caution is not used. Use
filtered fuel only when priming the filter. Prime through filtered fuel only when priming the filter. Prime through
the series of small holes on the top of the filter. DO the series of small holes on the top of the filter. DO
NOT prime the filter through the center hold. NOT prime the filter through the center hold.
Fuel Filters — MACK MP Engines Fuel Filters — MACK MP Engines

MACK MP engines utilize a spin-on primary and secondary fuel filters. MACK MP engines utilize a spin-on primary and secondary fuel filters.
Both filters are located on the right-hand side of the engine. Both filters are located on the right-hand side of the engine.
28 28

Figure 28 — Fuel Filters — MACK MP Engine Figure 28 — Fuel Filters — MACK MP Engine
1. Secondary Fuel Filter 2. Primary Fuel Filter 1. Secondary Fuel Filter 2. Primary Fuel Filter
124 124
The primary fuel filter on MACK MP engines incorporates a plastic The primary fuel filter on MACK MP engines incorporates a plastic
water separator bowl. Additionally, the plastic bowl includes a water-in- water separator bowl. Additionally, the plastic bowl includes a water-in-
fuel sensor. A warning lamp on the instrument panel illuminates when fuel sensor. A warning lamp on the instrument panel illuminates when
water is detected in the fuel. Refer to “Fuel/Water Separator” section. water is detected in the fuel. Refer to “Fuel/Water Separator” section.
There are optional fuel filter systems (such as Davco, There are optional fuel filter systems (such as Davco,
Conmet, etc.) available for MACK MP engines. Conmet, etc.) available for MACK MP engines.
These fuel filter systems use a single remote-mounted These fuel filter systems use a single remote-mounted
filter, eliminating the spin-on primary and secondary filter, eliminating the spin-on primary and secondary
filters. For service information concerning these filters, filters. For service information concerning these filters,
refer to the specific fuel filter manufacturer’s service refer to the specific fuel filter manufacturer’s service
literature. literature.
125 125
Primary Fuel Filter Replacement Procedures — MACK MP Primary Fuel Filter Replacement Procedures — MACK MP
Engines Engines
At each specified oil and filter change interval, change the primary fuel At each specified oil and filter change interval, change the primary fuel
filter as follows: filter as follows:
29 29

Figure 29 — MACK MP Primary Fuel Filter Figure 29 — MACK MP Primary Fuel Filter
1. Primary Filter 3. Water-in-Fuel Sensor Harness 1. Primary Filter 3. Water-in-Fuel Sensor Harness
2. Water Separator Bowl 4. Drain Assembly 2. Water Separator Bowl 4. Drain Assembly
1. Thoroughly wash the area around the fuel filter and mounting 1. Thoroughly wash the area around the fuel filter and mounting
adapter mating area with a suitable solvent and blow dry with adapter mating area with a suitable solvent and blow dry with
compressed air. compressed air.
2. Disconnect the water-in-fuel sensor harness connector from the 2. Disconnect the water-in-fuel sensor harness connector from the
plastic water separator bowl. plastic water separator bowl.
3. Using tool J 24783, remove the primary filter. 3. Using tool J 24783, remove the primary filter.
126 126
4. While holding the filter above a suitable container, open the drain 4. While holding the filter above a suitable container, open the drain
valve on the plastic water separator bowl and allow the fuel in the valve on the plastic water separator bowl and allow the fuel in the
bowl to drain. Dispose of the drained fuel in an environmentally bowl to drain. Dispose of the drained fuel in an environmentally
safe manner. safe manner.
5. Unscrew the plastic separator bowl from the bottom of the spin-on 5. Unscrew the plastic separator bowl from the bottom of the spin-on
primary filter cartridge. primary filter cartridge.
6. Apply a thin film of clean engine oil to the water separator bowl 6. Apply a thin film of clean engine oil to the water separator bowl
O-ring on the bottom of the new primary filter cartridge. O-ring on the bottom of the new primary filter cartridge.
7. Install the plastic water separator bowl to the primary filter 7. Install the plastic water separator bowl to the primary filter
cartridge, and tighten the bowl by hand 1/4 to 1/2 turn after the cartridge, and tighten the bowl by hand 1/4 to 1/2 turn after the
bowl contacts the O-ring. bowl contacts the O-ring.
8. Apply a thin film of clean engine oil to the sealing gasket of the 8. Apply a thin film of clean engine oil to the sealing gasket of the
new filter cartridge. new filter cartridge.
9. Prime the filter by pouring clean filter fuel through the series of 9. Prime the filter by pouring clean filter fuel through the series of
small holes at the top of the filter to the installation fill line. DO small holes at the top of the filter to the installation fill line. DO
NOT prime the filter through the center hole. Use care to avoid NOT prime the filter through the center hole. Use care to avoid
dirt entering the center hole of the filter. dirt entering the center hole of the filter.
10. Install the new filter and tighten an additional 1/2 to 3/4 turn by 10. Install the new filter and tighten an additional 1/2 to 3/4 turn by
hand after the gasket contacts the base. hand after the gasket contacts the base.
11. Reconnect the water-in-fuel sensor harness connector. 11. Reconnect the water-in-fuel sensor harness connector.
12. Prime the engine as required prior to starting the engine (refer to 12. Prime the engine as required prior to starting the engine (refer to
“Priming the Fuel System — MACK MP Engines” on page 129). “Priming the Fuel System — MACK MP Engines” on page 129).
13. Start the engine and check for leaks. 13. Start the engine and check for leaks.
127 127
Secondary Fuel Filter Replacement Procedures Secondary Fuel Filter Replacement Procedures
At each specified oil and filter change interval, change the secondary At each specified oil and filter change interval, change the secondary
fuel filter as follows: fuel filter as follows:
Because of ice buildup in the fuel system or fuel Because of ice buildup in the fuel system or fuel
waxing which can clog fuel filters, it may be necessary waxing which can clog fuel filters, it may be necessary
to reduce the time or mileage interval between fuel to reduce the time or mileage interval between fuel
filter changes during extremely cold weather. filter changes during extremely cold weather.
To install a new filter: To install a new filter:

1. Thoroughly wash the area around the fuel filter and mounting 1. Thoroughly wash the area around the fuel filter and mounting
adaptor mating area with a suitable solvent and blow dry with adaptor mating area with a suitable solvent and blow dry with
compressed air. compressed air.
2. Using tool J 24783, remove the old filters. 2. Using tool J 24783, remove the old filters.
3. Apply a thin film of clean engine oil to the sealing gasket of the 3. Apply a thin film of clean engine oil to the sealing gasket of the
new filters. new filters.
4. Prime the filter by pouring clean filtered fuel through the series of 4. Prime the filter by pouring clean filtered fuel through the series of
small holes at the top of the filter. DO NOT prime the filter through small holes at the top of the filter. DO NOT prime the filter through
the center hole. Use care to avoid dirt entering the center hole of the center hole. Use care to avoid dirt entering the center hole of
the filter. the filter.
5. Install the new filters and tighten an additional 3/4 to 1 turn by 5. Install the new filters and tighten an additional 3/4 to 1 turn by
hand after the gasket contacts the base. hand after the gasket contacts the base.
6. Prime the engine as required prior to starting the engine (refer to 6. Prime the engine as required prior to starting the engine (refer to
“Priming the Fuel System — MACK MP Engines” on page 129). “Priming the Fuel System — MACK MP Engines” on page 129).
7. Start the engine and check for leaks. 7. Start the engine and check for leaks.
128 128
Priming the Fuel System — MACK MP Engines Priming the Fuel System — MACK MP Engines
On MACK MP engines, the priming pump is located on the primary fuel On MACK MP engines, the priming pump is located on the primary fuel
filter mounting adapter. Prime the fuel system as follows: filter mounting adapter. Prime the fuel system as follows:
Before working on or inspecting a vehicle, apply Before working on or inspecting a vehicle, apply
the parking brakes, place the transmission in the parking brakes, place the transmission in
neutral and block the wheels to prevent the vehicle neutral and block the wheels to prevent the vehicle
from moving. Failure to do so can result in from moving. Failure to do so can result in
unexpected vehicle movement and cause severe unexpected vehicle movement and cause severe
personal injury or death. personal injury or death.
To avoid potential fire hazard, do not service any To avoid potential fire hazard, do not service any
part of the fuel system while smoking, or in the part of the fuel system while smoking, or in the
presence of flames, sparks or hot surfaces. Do not presence of flames, sparks or hot surfaces. Do not
service the fuel system while the engine is service the fuel system while the engine is
running. Failure to follow these precautions can running. Failure to follow these precautions can
result in a fire. To guard against burns from direct result in a fire. To guard against burns from direct
contact with hot fuel, wear adequate protective contact with hot fuel, wear adequate protective
clothing (face shield, heavy gloves, apron, etc.) clothing (face shield, heavy gloves, apron, etc.)
when working on a hot engine. when working on a hot engine.
DO NOT work near the fan while the engine is DO NOT work near the fan while the engine is
running. The engine fan can engage at any time running. The engine fan can engage at any time
without warning, resulting in serious injury. Before without warning, resulting in serious injury. Before
turning the ignition on, make sure that no one is turning the ignition on, make sure that no one is
near the fan. near the fan.
129 129
There are NO bleed nipples that must be opened in There are NO bleed nipples that must be opened in
order to prime the fuel system. order to prime the fuel system.
1. Unlock the primer pump handle by pushing the handle downward 1. Unlock the primer pump handle by pushing the handle downward
and then turning it counterclockwise. and then turning it counterclockwise.
30 30

Figure 30 — Unlocking Fuel System Primer Pump Handle Figure 30 — Unlocking Fuel System Primer Pump Handle
2. Operate the pump handle until pumping effort increases. 2. Operate the pump handle until pumping effort increases.
31 31

Figure 31 — Pumping Hand Primer Pump Figure 31 — Pumping Hand Primer Pump
130 130
With a fuel system that is completely empty, 200 or With a fuel system that is completely empty, 200 or
more strokes of the pump may be necessary to more strokes of the pump may be necessary to
properly prime the system. properly prime the system.
3. When the fuel system is primed, lock the primer pump handle by 3. When the fuel system is primed, lock the primer pump handle by
pushing it fully into the housing and turning it clockwise. pushing it fully into the housing and turning it clockwise.
4. Start the engine and run it at 1000 rpm for approximately 4. Start the engine and run it at 1000 rpm for approximately
5 minutes to purge any remaining air from the system. 5 minutes to purge any remaining air from the system.
If the engine does not start after performing the above If the engine does not start after performing the above
priming procedure, contact your local MACK dealer for priming procedure, contact your local MACK dealer for
assistance. assistance.
131 131
Fuel/Water Separator — MACK MP Engines Fuel/Water Separator — MACK MP Engines

The primary fuel filter on MACK MP engines includes a plastic water The primary fuel filter on MACK MP engines includes a plastic water
separator bowl with an integral water-in-fuel sensor and a drain separator bowl with an integral water-in-fuel sensor and a drain
assembly. A warning lamp on the instrument panel illuminates when assembly. A warning lamp on the instrument panel illuminates when
water is detected in the fuel. When the lamp illuminates, drain the water is detected in the fuel. When the lamp illuminates, drain the
water from the separator by opening the drain valve and allowing the water from the separator by opening the drain valve and allowing the
water to drain from the bowl into a suitable container. When fuel begins water to drain from the bowl into a suitable container. When fuel begins
to drain, close the valve and tighten to 0.655 N폷m (5 lb-in). Dispose of to drain, close the valve and tighten to 0.655 N폷m (5 lb-in). Dispose of
the drained water/fuel in an environmentally safe manner. the drained water/fuel in an environmentally safe manner.
32 32

Figure 32 — Water Separator Drain Valve — MACK MP Engines Figure 32 — Water Separator Drain Valve — MACK MP Engines
DO NOT drain the water separator bowl while the DO NOT drain the water separator bowl while the
engine is running. engine is running.
132 132
ELECTRICAL SYSTEM ELECTRICAL SYSTEM

Batteries Batteries
A maintenance-free battery does not require the addition of water for A maintenance-free battery does not require the addition of water for
its normal expected life. Typical features include heavy-duty its normal expected life. Typical features include heavy-duty
construction and a wrought lead-calcium grid to resist vibration, shock, construction and a wrought lead-calcium grid to resist vibration, shock,
overcharge, heat and thermal runaway. Nevertheless, these batteries overcharge, heat and thermal runaway. Nevertheless, these batteries
are vulnerable to the ravages of cold weather operation if totally are vulnerable to the ravages of cold weather operation if totally
ignored. ignored.
33 33

Figure 33 — Battery Figure 33 — Battery
Be sure that the batteries used in a particular vehicle are rated for the Be sure that the batteries used in a particular vehicle are rated for the
specified Cold Cranking Amperes (CCAs) necessary to ensure reliable specified Cold Cranking Amperes (CCAs) necessary to ensure reliable
cold weather starts. This is important, since even well-maintained cold weather starts. This is important, since even well-maintained
batteries chilled to −18°C (0°F) may temporarily be capable of batteries chilled to −18°C (0°F) may temporarily be capable of
providing only 40% of their rated capacity at 27°C (80°F). providing only 40% of their rated capacity at 27°C (80°F).
Keep the terminals clean to prevent formation of power-robbing Keep the terminals clean to prevent formation of power-robbing
corrosion. corrosion.
In winter, to avoid freezing the electrolyte, the battery must be fully In winter, to avoid freezing the electrolyte, the battery must be fully
charged. A fully discharged battery will freeze solid at −5°C (23°F) and charged. A fully discharged battery will freeze solid at −5°C (23°F) and
possibly sustain permanent damage. possibly sustain permanent damage.
Before the onset of cold weather, be sure to protect this vital Before the onset of cold weather, be sure to protect this vital
component by monitoring its condition as well as inspecting the component by monitoring its condition as well as inspecting the
charging and starting systems. charging and starting systems.
133 133
Battery Warmer Battery Warmer

A battery warmer can be added to raise the temperature of the battery A battery warmer can be added to raise the temperature of the battery
core and facilitate quick starting in cold weather. core and facilitate quick starting in cold weather.
Battery Condition Battery Condition

The first procedure when testing a battery is to check for external The first procedure when testing a battery is to check for external
damage such as a cracked case, loose or corroded terminals, or signs damage such as a cracked case, loose or corroded terminals, or signs
of excessive gassing or overcharging. of excessive gassing or overcharging.
A battery must be fully charged before a load test is performed. Test A battery must be fully charged before a load test is performed. Test
the battery with a hydrometer to determine the level of charge. the battery with a hydrometer to determine the level of charge.
On maintenance-free batteries equipped with a built-in hydrometer On maintenance-free batteries equipped with a built-in hydrometer
(eye), the battery condition is interpreted as follows: (eye), the battery condition is interpreted as follows:
34 34
Figure 34 — Battery Condition Figure 34 — Battery Condition
134 134
앫 Green dot visible — Any green appearance should be 앫 Green dot visible — Any green appearance should be
interpreted as a green dot and means that the battery is at or interpreted as a green dot and means that the battery is at or
above a 65% state of charge and is ready for use or testing. This above a 65% state of charge and is ready for use or testing. This
does not automatically mean that the battery is in good condition. does not automatically mean that the battery is in good condition.
앫 Dark — green dot not visible (black dot) — This indicates that 앫 Dark — green dot not visible (black dot) — This indicates that
the battery is below a 65% state of charge and must be charged the battery is below a 65% state of charge and must be charged
before testing. A black dot does not mean that the battery is before testing. A black dot does not mean that the battery is
automatically bad. automatically bad.
앫 Clear or light yellow — This means that the electrolyte level is 앫 Clear or light yellow — This means that the electrolyte level is
below the level of the built-in hydrometer, which may have been below the level of the built-in hydrometer, which may have been
caused by tipping of the battery, a cracked case, or overcharging. caused by tipping of the battery, a cracked case, or overcharging.
This battery should be replaced. This battery should be replaced.
135 135
Charging Charging
Charging should be conducted carefully under controlled conditions. Charging should be conducted carefully under controlled conditions.
Never charge a frozen battery. If a frozen battery is suspected, thaw it Never charge a frozen battery. If a frozen battery is suspected, thaw it
in a warm area for several hours before charging. in a warm area for several hours before charging.
The following chart shows the normal charging times necessary to The following chart shows the normal charging times necessary to
reach a full charge at 26°C (80°F). In colder temperatures, the reach a full charge at 26°C (80°F). In colder temperatures, the
necessary charging time may increase. necessary charging time may increase.
Charging Time to Full Charge at 80°F** Charging Time to Full Charge at 80°F**
Open Battery Open Battery

Circuit Specific State of at 60 at 50 at 40 at 30 at 20 at 10 Circuit Specific State of at 60 at 50 at 40 at 30 at 20 at 10
Voltage Gravity* Charge amps amps amps amps amps amps Voltage Gravity* Charge amps amps amps amps amps amps
12.6 1.265 100% Full Charge 12.6 1.265 100% Full Charge
12.4 1.225 75% 15 min. 20 min. 27 min. 35 min. 48 min. 90 min. 12.4 1.225 75% 15 min. 20 min. 27 min. 35 min. 48 min. 90 min.
* Correct for temperature. * Correct for temperature.

** If colder, it will take longer. ** If colder, it will take longer.
136 136
COMPLETELY DISCHARGED BATTERIES COMPLETELY DISCHARGED BATTERIES

Extremely cold or completely discharged batteries may not initially Extremely cold or completely discharged batteries may not initially
show a charge since the electrolyte is nearly pure water and, therefore, show a charge since the electrolyte is nearly pure water and, therefore,
a poor conductor. As the acid level in the electrolyte increases during a poor conductor. As the acid level in the electrolyte increases during
charging, the charging current will also increase. Use the following charging, the charging current will also increase. Use the following
procedure when charging a completely discharged battery: procedure when charging a completely discharged battery:
1. Measure the voltage at the battery terminals. If it is below 1. Measure the voltage at the battery terminals. If it is below
10 volts, current will be very low and may not show up on many 10 volts, current will be very low and may not show up on many
battery charger ammeters. battery charger ammeters.
2. Set the charger on the high setting. 2. Set the charger on the high setting.
3. Some chargers have a polarity protection feature which prevents 3. Some chargers have a polarity protection feature which prevents
accidental reversal of the charger leads. A completely discharged accidental reversal of the charger leads. A completely discharged
battery will not have enough voltage to override this feature, battery will not have enough voltage to override this feature,
making it appear that the battery will not accept a charge. Check making it appear that the battery will not accept a charge. Check
the charger manufacturer’s instructions on how to bypass this the charger manufacturer’s instructions on how to bypass this
feature. feature.
4. Once the battery starts to accept a charge, the charging rate will 4. Once the battery starts to accept a charge, the charging rate will
rise very rapidly. Carefully monitor the ammeter to prevent too- rise very rapidly. Carefully monitor the ammeter to prevent too-
high a charging rate. high a charging rate.
5. Proceed to charge battery at one-tenth of its rated capacity for 5. Proceed to charge battery at one-tenth of its rated capacity for
one-half hour. one-half hour.
Example: For battery rated at 64 amps, charge at 6.4 amp setting Example: For battery rated at 64 amps, charge at 6.4 amp setting
(64A × 1/10 = 6.4A) for one-half hour. (64A × 1/10 = 6.4A) for one-half hour.
Batteries with very low voltage (below 11.6 volts) or Batteries with very low voltage (below 11.6 volts) or
those that do not initially accept a charge are not those that do not initially accept a charge are not
necessarily defective. Batteries that have been necessarily defective. Batteries that have been
discharged for long periods of time may be heavily discharged for long periods of time may be heavily
sulfated or hydrated (containing lead shorts that cause sulfated or hydrated (containing lead shorts that cause
the battery to self-discharge). To accept a charge, the battery to self-discharge). To accept a charge,
batteries with either of these conditions may require a batteries with either of these conditions may require a
longer charging time or a very high initial charge. longer charging time or a very high initial charge.
137 137
Use the following chart to determine the time required for the battery to Use the following chart to determine the time required for the battery to
begin accepting a measurable charge. (If the battery has not started to begin accepting a measurable charge. (If the battery has not started to
accept a charge after the specified time, it should be replaced.) accept a charge after the specified time, it should be replaced.)
Charger Voltage Hours Charger Voltage Hours
16.0 or more Up to 4 16.0 or more Up to 4
14.0 to 15.9 Up to 8 14.0 to 15.9 Up to 8
13.9 or less Up to 16 13.9 or less Up to 16
Load Test Load Test

A battery must be fully charged before performing a load test. To load- A battery must be fully charged before performing a load test. To load-
test a battery that is fully charged, proceed as follows: test a battery that is fully charged, proceed as follows:
1. Connect a load tester and voltmeter across the battery terminals. 1. Connect a load tester and voltmeter across the battery terminals.
2. Apply a load so that a figure of 300 amps is obtained for 2. Apply a load so that a figure of 300 amps is obtained for
15 seconds to remove the battery surface charge. 15 seconds to remove the battery surface charge.
3. Wait 60 seconds to let the battery recover and then apply the 3. Wait 60 seconds to let the battery recover and then apply the
proper test load to the battery to determine its condition. To get proper test load to the battery to determine its condition. To get
the proper load, use half the cranking performance rating. Read the proper load, use half the cranking performance rating. Read
the voltage after 15 seconds. Remember that the minimum the voltage after 15 seconds. Remember that the minimum
voltage varies according to temperature. Consult the following voltage varies according to temperature. Consult the following
chart for the proper specification. If the battery voltage does not chart for the proper specification. If the battery voltage does not
fall below the minimum test voltage after 15 seconds, the battery fall below the minimum test voltage after 15 seconds, the battery
is acceptable for use. is acceptable for use.
138 138
Load Test Temperature Correction Load Test Temperature Correction
Temperature Temperature
Minimum Voltage °C °F Minimum Voltage °C °F
9.6 21 70 9.6 21 70
9.5 16 60 9.5 16 60
9.4 10 50 9.4 10 50
9.3 4 40 9.3 4 40
9.1 −1 30 9.1 −1 30
8.9 −7 20 8.9 −7 20
8.7 −12 10 8.7 −12 10
8.5 −18 0 8.5 −18 0
139 139
Precautions When Installing Electrical Equipment Precautions When Installing Electrical Equipment
Connecting electrically powered or electrically controlled equipment to Connecting electrically powered or electrically controlled equipment to
a vehicle may cause interference with other vehicle electrical or a vehicle may cause interference with other vehicle electrical or
electronic equipment (such as ABS systems, Rollover Stability electronic equipment (such as ABS systems, Rollover Stability
Systems, etc.). The amount of interference depends upon the Systems, etc.). The amount of interference depends upon the
operating frequency of any new signals and the degree to which operating frequency of any new signals and the degree to which
transient signals are coupled to the vehicle system. transient signals are coupled to the vehicle system.
Whenever new electrical equipment is installed, it is Whenever new electrical equipment is installed, it is
the obligation of the installer to ensure that the new the obligation of the installer to ensure that the new
equipment does not interfere with the proper operation equipment does not interfere with the proper operation
of all other electrical systems on the vehicle. of all other electrical systems on the vehicle.
If new electrical equipment is installed, a vehicle checkout procedure If new electrical equipment is installed, a vehicle checkout procedure
should be performed. should be performed.
1. Perform the checkout procedure under the following conditions: 1. Perform the checkout procedure under the following conditions:
앫 Engine running 앫 Engine running
앫 Brake system air pressure in operating range 앫 Brake system air pressure in operating range
앫 Vehicle stationary 앫 Vehicle stationary
앫 Brake pedal fully depressed 앫 Brake pedal fully depressed
2. Operate the new equipment under all starting, running and 2. Operate the new equipment under all starting, running and
sutdown conditions. sutdown conditions.
3. Listen for signs of air exhausting from the ABS modulator valves 3. Listen for signs of air exhausting from the ABS modulator valves
(which is an indication of an interference condition). (which is an indication of an interference condition).
4. Correct all interference conditions before operating the vehicle. 4. Correct all interference conditions before operating the vehicle.
140 140
The center pin of the standard seven-pin trailer The center pin of the standard seven-pin trailer
electrical connector has been standardized as the electrical connector has been standardized as the
dedicated connection for uninterrupted power for dedicated connection for uninterrupted power for
trailer ABS. This pin is always hot when the tractor trailer ABS. This pin is always hot when the tractor
ignition is turned on. ignition is turned on.
Some trailers manufactured prior to the trailer ABS Some trailers manufactured prior to the trailer ABS
regulations may use the center pin to power regulations may use the center pin to power
certain trailer auxiliary equipment. The possibility certain trailer auxiliary equipment. The possibility
exists that this auxiliary equipment may be exists that this auxiliary equipment may be
unexpectedly activated by the truck or tractor unexpectedly activated by the truck or tractor
electrical system, resulting in personal injury or electrical system, resulting in personal injury or
damage to equipment. Caution must be used when damage to equipment. Caution must be used when
connecting the trailer electrical connector to connecting the trailer electrical connector to
ensure that power to the center pin will not ensure that power to the center pin will not
unintentionally activate any trailer auxiliary unintentionally activate any trailer auxiliary
equipment. equipment.
MACK ROAD STABILITY ADVANTAGE MACK ROAD STABILITY ADVANTAGE

The MACK Road Stability Advantage (RSA) is an available option on The MACK Road Stability Advantage (RSA) is an available option on
certain MACK highway tractors and straight trucks. The RSA system, certain MACK highway tractors and straight trucks. The RSA system,
which is based on the Bendix ABS-6 Advanced with ESP (Electronic which is based on the Bendix ABS-6 Advanced with ESP (Electronic
Stability Program) System, aids the operator in maintaining control of Stability Program) System, aids the operator in maintaining control of
the vehicle during jackknife or rollover events by applying select brakes the vehicle during jackknife or rollover events by applying select brakes
and reducing engine power as required by the specific situation. This and reducing engine power as required by the specific situation. This
system is integral with the anti-lock brake system and uses the system is integral with the anti-lock brake system and uses the
standard ABS components (such as wheel speed sensors and standard ABS components (such as wheel speed sensors and
modulator valves). Additionally, a steering angle sensor and a yaw rate/ modulator valves). Additionally, a steering angle sensor and a yaw rate/
lateral acceleration sensor package provides information concerning lateral acceleration sensor package provides information concerning
vehicle movement to the electronic control unit. vehicle movement to the electronic control unit.
141 141
Before delivery to the end user, a “parameter set” tuned for the specific Before delivery to the end user, a “parameter set” tuned for the specific
vehicle and the VIN for the chassis are loaded into the ABS electronic vehicle and the VIN for the chassis are loaded into the ABS electronic
control unit. This ensures optimal performance of the MACK RSA control unit. This ensures optimal performance of the MACK RSA
system for the specific vehicle. system for the specific vehicle.
Alterations and modifications to an RSA-equipped vehicle, such as Alterations and modifications to an RSA-equipped vehicle, such as
wheel base changes (either lengthening or shortening), the addition of wheel base changes (either lengthening or shortening), the addition of
an auxiliary lift axle or the removal of a factory-installed lift axle, or an auxiliary lift axle or the removal of a factory-installed lift axle, or
major body changes, such as conversion of a tractor to a truck or an major body changes, such as conversion of a tractor to a truck or an
axle, suspension or steering system component modification, are NOT axle, suspension or steering system component modification, are NOT
allowed, as these changes will adversely affect performance of the allowed, as these changes will adversely affect performance of the
road stability system. Should such changes be unavoidable, the road stability system. Should such changes be unavoidable, the
system must be disabled by having a qualified technician replace the system must be disabled by having a qualified technician replace the
Bendix Advanced EC-60™ (ABS control unit with ESP) with a Bendix Advanced EC-60™ (ABS control unit with ESP) with a
Bendix Premium EC-60™ ECU (ABS control unit without ESP). Bendix Premium EC-60™ ECU (ABS control unit without ESP).
Failure to disable the RSA system on a vehicle that Failure to disable the RSA system on a vehicle that
has been modified or altered will result in serious has been modified or altered will result in serious
vehicle braking and performance issues, including vehicle braking and performance issues, including
unnecessary system interventions. These unnecessary system interventions. These
interventions could lead to a loss of vehicle interventions could lead to a loss of vehicle
control. control.
In addition to disabling the system, any cab labels, In addition to disabling the system, any cab labels,
such as warning and caution labels relating to the such as warning and caution labels relating to the
Bendix ABS-6 Advanced with ESP system Bendix ABS-6 Advanced with ESP system
located on the sun visor must be removed, and located on the sun visor must be removed, and
notations must be made in the operator’s manuals notations must be made in the operator’s manuals
so that the vehicle operator has a clear so that the vehicle operator has a clear
understanding as to which ABS options are understanding as to which ABS options are
installed on the vehicle. installed on the vehicle.
The location of the yaw rate/lateral acceleration sensor must not be The location of the yaw rate/lateral acceleration sensor must not be
altered. altered.
142 142
Aftermarket steering wheels must not be used. Only OEM-supplied Aftermarket steering wheels must not be used. Only OEM-supplied
replacement steering wheels should be used. During any procedure replacement steering wheels should be used. During any procedure
that involves removal and reinstallation or replacement of the OEM that involves removal and reinstallation or replacement of the OEM
steering wheel, care must be used not to crush or damage the steering steering wheel, care must be used not to crush or damage the steering
angle sensor which is mounted on the steering column. angle sensor which is mounted on the steering column.
The following changes MUST NOT be made to an “as-built” RSA- The following changes MUST NOT be made to an “as-built” RSA-
equipped vehicle: equipped vehicle:
앫 Changes to maximum steering angle (to the left or right) 앫 Changes to maximum steering angle (to the left or right)
앫 Changes to steer axle and/or drive axle track width 앫 Changes to steer axle and/or drive axle track width
앫 Changing front and/or rear brake drums to drums having a 앫 Changing front and/or rear brake drums to drums having a
different flange thickness (thus changing the track width of the different flange thickness (thus changing the track width of the
vehicle) vehicle)
The ABS with ESP ECU requires a precise rolling circumference ratio The ABS with ESP ECU requires a precise rolling circumference ratio
between the front steer axle and the rear drive axles for optimum between the front steer axle and the rear drive axles for optimum
performance of the system. For this reason, the system continuously performance of the system. For this reason, the system continuously
calculates the precise ratio and stores the information in the ECU calculates the precise ratio and stores the information in the ECU
memory. memory.
Effectiveness of the RSA system relies on the Effectiveness of the RSA system relies on the
accuracy of the reported vehicle speed. If major accuracy of the reported vehicle speed. If major
changes to tire sizes are made, such that changes to changes to tire sizes are made, such that changes to
the vehicle speedometer/odometer settings are the vehicle speedometer/odometer settings are
required, the ABS with ESP ECU must be required, the ABS with ESP ECU must be
reprogrammed with the new values by a qualified reprogrammed with the new values by a qualified
technician. technician.
143 143
LUBRICATION LUBRICATION
Gear Oil Change Interval (Transmissions and Carriers) Gear Oil Change Interval (Transmissions and Carriers)
All Highway Chassis All Highway Chassis
Kilometers (Miles)* Time* Kilometers (Miles)* Time*
402 000 km (250,000 miles) 2 years 402 000 km (250,000 miles) 2 years
An extended drain interval of 804 600 km/ An extended drain interval of 804 600 km/
500,000 milesor three years, whichever occurs first, is 500,000 milesor three years, whichever occurs first, is
permissible for MACK-geared components used in permissible for MACK-geared components used in
highway chassis provided MACK specification GO-J highway chassis provided MACK specification GO-J
PLUS gear lubricant is used. Otherwise, gear lubricant PLUS gear lubricant is used. Otherwise, gear lubricant
must be changed at the two-year, 402 300 km/ must be changed at the two-year, 402 300 km/
250,000 mile interval, whichever occurs first. 250,000 mile interval, whichever occurs first.
144 144
All Vocational Chassis All Vocational Chassis
Kilometers (Miles)* Time* Kilometers (Miles)* Time*
64 000 km (40,000 miles) 1 year/1200 hours 64 000 km (40,000 miles) 1 year/1200 hours
An extended drain interval of 128 800 km/ An extended drain interval of 128 800 km/
80,000 miles, one year or 1,200 hours, whichever 80,000 miles, one year or 1,200 hours, whichever
occurs first, is permissible for MACK-geared occurs first, is permissible for MACK-geared
components used in vocational chassis provided that components used in vocational chassis provided that
MACK specification GO-J PLUS gear lubricant is MACK specification GO-J PLUS gear lubricant is
used. Otherwise, gear lubricant must be changed at used. Otherwise, gear lubricant must be changed at
the one-year, 1200-hour or 64 000 km/40,000 mile the one-year, 1200-hour or 64 000 km/40,000 mile
interval, whichever occurs first. interval, whichever occurs first.
An SAE 50 grade synthetic transmission oil, TO-A An SAE 50 grade synthetic transmission oil, TO-A
PLUS, is available for use in MACK transmissions as PLUS, is available for use in MACK transmissions as
an extended drain interval lubricant. TO-A PLUS is for an extended drain interval lubricant. TO-A PLUS is for
use in transmissions only, and not to be used in any use in transmissions only, and not to be used in any
other geared components. Drain intervals for TO-A other geared components. Drain intervals for TO-A
PLUS transmission lubricant are 804 600 km/ PLUS transmission lubricant are 804 600 km/
500,000 miles or three years (whichever occurs first) 500,000 miles or three years (whichever occurs first)
for highway applications, and 128 800 km/ for highway applications, and 128 800 km/
80,000 miles, one year or 1,200 hours (whichever 80,000 miles, one year or 1,200 hours (whichever
occurs first) for vocational applications. occurs first) for vocational applications.
145 145
Driveshaft Lubrication Driveshaft Lubrication

The following information pertains to lubrication intervals for Spicer The following information pertains to lubrication intervals for Spicer
Life™ SPL-170, SPL-250, SPL-170XL and SPL-250XL driveshafts and Life™ SPL-170, SPL-250, SPL-170XL and SPL-250XL driveshafts and
ArvinMeritor™ RPL20 and RPL25 Permalube™ series and 92N ArvinMeritor™ RPL20 and RPL25 Permalube™ series and 92N
Permalube™ wing-style driveshafts. For all other driveshafts, use the Permalube™ wing-style driveshafts. For all other driveshafts, use the
regular chassis lubrication intervals as outlined. regular chassis lubrication intervals as outlined.
SPICER LIFE™ SPL-170 AND SPL-250 DRIVESHAFT — U-JOINT SPICER LIFE™ SPL-170 AND SPL-250 DRIVESHAFT — U-JOINT
Spicer Life™ SPL-170 and SPL-250 driveshaft U-joints must be Spicer Life™ SPL-170 and SPL-250 driveshaft U-joints must be
lubricated at the following intervals: lubricated at the following intervals:
앫 Highway Chassis: Every 161 000 km (100,000 miles) or 앫 Highway Chassis: Every 161 000 km (100,000 miles) or
6 months* 6 months*
— Severe Service: every 600 hours, 32 000 km (20,000 miles) — Severe Service: every 600 hours, 32 000 km (20,000 miles)
or 180 days* or 180 days*
— Extra Severe Service: every 375 hours, 19 000 km — Extra Severe Service: every 375 hours, 19 000 km
(12,000 miles) or 90 days* (12,000 miles) or 90 days*
Slip-joints used with the SPL-170 and SPL-250 series Slip-joints used with the SPL-170 and SPL-250 series
driveshafts are “lubed for life” and protected by a driveshafts are “lubed for life” and protected by a
bellows. Lubrication of these slip-joints is not required bellows. Lubrication of these slip-joints is not required
and the bellows must not be disturbed. and the bellows must not be disturbed.
146 146
SPICER LIFE™ SPL-170XL AND SPL-250XL DRIVESHAFT — SPICER LIFE™ SPL-170XL AND SPL-250XL DRIVESHAFT —
U-JOINT LUBRICATION U-JOINT LUBRICATION
Spicer Life™ XL series driveshafts are equipped with “extended- Spicer Life™ XL series driveshafts are equipped with “extended-
lubrication” U-joints. These U-joints are easily identified by the blue lubrication” U-joints. These U-joints are easily identified by the blue
plastic cover in the center of the U-joint cross where the grease fitting is plastic cover in the center of the U-joint cross where the grease fitting is
usually located. The XL U-joints must be lubricated initially at the usually located. The XL U-joints must be lubricated initially at the
following intervals: following intervals:
앫 Highway Chassis: 560 000 km (350,000 miles) or 3 years* 앫 Highway Chassis: 560 000 km (350,000 miles) or 3 years*
앫 Vocational Chassis (includes city driving and on/off highway): 앫 Vocational Chassis (includes city driving and on/off highway):
161 000 km (100,000 miles) or 1 year* 161 000 km (100,000 miles) or 1 year*
After the initial lubrication outlined above, Spicer Life™ XL series After the initial lubrication outlined above, Spicer Life™ XL series
driveshafts must be lubricated at the following intervals: driveshafts must be lubricated at the following intervals:
앫 Highway Chassis: 161 000 km (100,000 miles) or 6 months* 앫 Highway Chassis: 161 000 km (100,000 miles) or 6 months*
— Severe Service: 600 hours, 32 000 km (20,000 miles) or — Severe Service: 600 hours, 32 000 km (20,000 miles) or
180 days* 180 days*
— Extra Severe Service: 375 hours, 19 000 km (12,000 miles) — Extra Severe Service: 375 hours, 19 000 km (12,000 miles)
or 90 days* or 90 days*
Slip-joints used with the SPL-170XL and SPL-250XL Slip-joints used with the SPL-170XL and SPL-250XL
series driveshafts are “lubed for life” and protected by series driveshafts are “lubed for life” and protected by
a bellows. Lubrication of these slip-joints is not a bellows. Lubrication of these slip-joints is not
required and the bellows must not be disturbed. required and the bellows must not be disturbed.
147 147
ARVINMERITOR™ RPL20 AND RPL25 PERMALUBE™ SERIES ARVINMERITOR™ RPL20 AND RPL25 PERMALUBE™ SERIES
DRIVESHAFTS DRIVESHAFTS
The U-joints and slip-joints on the RPL20 and RPL25 series The U-joints and slip-joints on the RPL20 and RPL25 series
driveshafts are permanently lubricated and sealed. Lubrication at driveshafts are permanently lubricated and sealed. Lubrication at
regular intervals is not required during the life of the driveshaft. regular intervals is not required during the life of the driveshaft.
ARVINMERITOR™ 92N PERMALUBE™ WING-STYLE ARVINMERITOR™ 92N PERMALUBE™ WING-STYLE

DRIVESHAFTS DRIVESHAFTS
The U-joints used on the 92N Permalube™ wing-style driveshafts are The U-joints used on the 92N Permalube™ wing-style driveshafts are
permanently lubricated and sealed. Lubrication at regular intervals is permanently lubricated and sealed. Lubrication at regular intervals is
not required for the life of the driveshaft. The slip-joints, however, must not required for the life of the driveshaft. The slip-joints, however, must
be lubricated at each specified chassis lubrication interval. be lubricated at each specified chassis lubrication interval.
Clutch Release Bearing Lubrication Clutch Release Bearing Lubrication

The clutch release bearing must be lubricated at each chassis The clutch release bearing must be lubricated at each chassis
lubrication interval. lubrication interval.
To ensure proper lubrication: To ensure proper lubrication:

앫 Check that the lube tube assembly (if equipped) is intact. 앫 Check that the lube tube assembly (if equipped) is intact.
앫 Apply grease to fitting until grease can be seen coming from the 앫 Apply grease to fitting until grease can be seen coming from the
back of the release bearing. back of the release bearing.
앫 It is recommended that grease be purged from the release 앫 It is recommended that grease be purged from the release
bearing during lubrication of the bearing. bearing during lubrication of the bearing.
앫 Apply grease to the release bearing yoke shaft, one fitting on 앫 Apply grease to the release bearing yoke shaft, one fitting on
each side of the transmission. each side of the transmission.
Recommended lubricant is NLGI No. 2EP grease. Recommended lubricant is NLGI No. 2EP grease.
148 148
RELEASE BEARING PADS: RELEASE BEARING PADS:

Apply a small amount of recommended grease between the release Apply a small amount of recommended grease between the release
bearing pads and the clutch release fork when lubricating the clutch bearing pads and the clutch release fork when lubricating the clutch
release bearing. release bearing.
RELEASE BEARING LUBE TUBE (IF EQUIPPED): RELEASE BEARING LUBE TUBE (IF EQUIPPED):
Lube tubes should be pre-lubed before installation. This is to remove Lube tubes should be pre-lubed before installation. This is to remove
air from the lube tube system to ensure lubricant is delivered to the air from the lube tube system to ensure lubricant is delivered to the
release bearing during initial installation. release bearing during initial installation.
Your new MACK truck has been prepared for delivery Your new MACK truck has been prepared for delivery
by your MACK Service Center. After delivery, oil by your MACK Service Center. After delivery, oil
change, filter change, and chassis lubrication intervals change, filter change, and chassis lubrication intervals
become your sole responsibility. become your sole responsibility.
It is important that components be filled with lubricants It is important that components be filled with lubricants
meeting the specifications as given in “LUBRICANT meeting the specifications as given in “LUBRICANT
SPECIFICATIONS” on page 267. SPECIFICATIONS” on page 267.
When checking oil levels, the vehicle must be parked When checking oil levels, the vehicle must be parked
on level ground and the units at normal operating on level ground and the units at normal operating
temperature. Components must be filled to the correct temperature. Components must be filled to the correct
level. DO NOT OVERFILL. level. DO NOT OVERFILL.
The oil and filter change intervals outlined in this The oil and filter change intervals outlined in this
manual pertain to MACK components. For information manual pertain to MACK components. For information
concerning oil and oil filter change intervals for vendor concerning oil and oil filter change intervals for vendor
components, refer to the specific vendor component components, refer to the specific vendor component
service literature. service literature.
149 149
35 35
Figure 35 — Bulldog Lubricants Figure 35 — Bulldog Lubricants
150 150
Oil and Filter Change — MACK MP Engines Oil and Filter Change — MACK MP Engines
Run the engine until normal operating temperature is reached, then Run the engine until normal operating temperature is reached, then
shut off and drain the oil before the engine cools. shut off and drain the oil before the engine cools.
Thoroughly clean the area around the filters before removing. Thoroughly clean the area around the filters before removing.
Using tool J 24783, remove the spin-on filters. Using tool J 24783, remove the spin-on filters.
36 36

Figure 36 — Spin-On Oil Filters Figure 36 — Spin-On Oil Filters
1. Spin-On Oil Filters 1. Spin-On Oil Filters
Prefill each new oil filter with 1.9 liters (2 quarts) of the recommended Prefill each new oil filter with 1.9 liters (2 quarts) of the recommended
engine oil. DO NOT allow any contaminants to enter the filters while engine oil. DO NOT allow any contaminants to enter the filters while
prefilling. prefilling.
Apply a thin film of engine oil to the sealing gasket of the new filters. Apply a thin film of engine oil to the sealing gasket of the new filters.
151 151
Install the filters and tighten an additional 3/4 to 1 turn after the gasket Install the filters and tighten an additional 3/4 to 1 turn after the gasket
contacts the base. contacts the base.
Fill the engine with the recommended engine oil (refer to Fill the engine with the recommended engine oil (refer to
“LUBRICANTS AND CAPACITIES” on page 288). “LUBRICANTS AND CAPACITIES” on page 288).
Check oil level and add oil as required. Check oil level and add oil as required.
The spin-on oil filters must be pre-filled at installation The spin-on oil filters must be pre-filled at installation
(refer to “Oil and Filter Change — MACK MP Engines” (refer to “Oil and Filter Change — MACK MP Engines”
on page 151). on page 151).
Check engine oil level prior to starting the engine. Oil Check engine oil level prior to starting the engine. Oil
level checks performed immediately after engine shut level checks performed immediately after engine shut
down will result in an inaccurate dipstick reading. down will result in an inaccurate dipstick reading.
Start the engine and check for leaks. Start the engine and check for leaks.
152 152
Oil Level Check Oil Level Check

Check engine oil level with the vehicle parked on level ground. The Check engine oil level with the vehicle parked on level ground. The
best time to check oil level is while the engine is COLD (prior to starting best time to check oil level is while the engine is COLD (prior to starting
at the beginning of the work day, or after the vehicle has sat at the beginning of the work day, or after the vehicle has sat
approximately 2 hours). At normal operating temperature (engine oil approximately 2 hours). At normal operating temperature (engine oil
temperature above 79.4°C [175°F]), oil level can be checked temperature above 79.4°C [175°F]), oil level can be checked
15 minutes after shut down. 15 minutes after shut down.
Failure to wait a sufficient amount of time (2 hours if Failure to wait a sufficient amount of time (2 hours if
engine oil temperature is below 79.4°C [175°F]) or engine oil temperature is below 79.4°C [175°F]) or
15 minutes if oil temperature is above 79.4°C [175°F]) 15 minutes if oil temperature is above 79.4°C [175°F])
will result in an inaccurate dipstick reading. will result in an inaccurate dipstick reading.
Fill to the correct level. DO NOT OVERFILL. Fill to the correct level. DO NOT OVERFILL.
Oil level must be between the add and full lines on the dipstick as Oil level must be between the add and full lines on the dipstick as
shown in Figure 37. shown in Figure 37.
37 37

Figure 37 — Dipstick Oil Level Check Figure 37 — Dipstick Oil Level Check
153 153
Dipstick and oil fill locations are shown in the illustrations below. On Dipstick and oil fill locations are shown in the illustrations below. On
conventional cabs, the oil fill tube and dipstick are located on the left- conventional cabs, the oil fill tube and dipstick are located on the left-
hand side of the engine. hand side of the engine.
38 38

Figure 38 — Conventional Cabs Oil Fill and Dipstick Location Figure 38 — Conventional Cabs Oil Fill and Dipstick Location
154 154
39 39

Figure 39 — Cab Forward Chassis Oil Fill and Dipstick Location Figure 39 — Cab Forward Chassis Oil Fill and Dipstick Location
Power Steering Fluid Change Power Steering Fluid Change
Beginning December 2005, Mack Trucks, Inc. began Beginning December 2005, Mack Trucks, Inc. began
phasing DEXRON III into production as the factory fill phasing DEXRON III into production as the factory fill
for the power steering system. Vehicles utilizing for the power steering system. Vehicles utilizing
DEXRON-type automatic transmission fluid in the DEXRON-type automatic transmission fluid in the
power steering system are identified by the label power steering system are identified by the label
affixed to the power steering reservoir. When adding affixed to the power steering reservoir. When adding
fluid to the power steering system, always check the fluid to the power steering system, always check the
label on the side of the reservoir and be sure to use label on the side of the reservoir and be sure to use
the correct fluid. the correct fluid.
155 155
Change the power steering fluid and filter once per year (D inspection Change the power steering fluid and filter once per year (D inspection
interval) for vehicles operating in highway operations, and twice per interval) for vehicles operating in highway operations, and twice per
year (C and D inspection intervals) for chassis operating in vocational year (C and D inspection intervals) for chassis operating in vocational
operations. Refill the power steering system with the same type of fluid operations. Refill the power steering system with the same type of fluid
originally used in the system. Refer to the label on the side of the originally used in the system. Refer to the label on the side of the
power steering reservoir for the correct fluid. Refer to “STEERING power steering reservoir for the correct fluid. Refer to “STEERING
SYSTEM LUBRICANTS AND CAPACITIES” on page 295. SYSTEM LUBRICANTS AND CAPACITIES” on page 295.
To avoid dirt from entering the steering system after To avoid dirt from entering the steering system after
the lines have been disconnected, clean around all the lines have been disconnected, clean around all
fittings and both hose connections at the power fittings and both hose connections at the power
steering gear. Also clean around the reservoir cover. steering gear. Also clean around the reservoir cover.
Run the vehicle until the engine reaches normal operating Run the vehicle until the engine reaches normal operating
temperature, then shut off the engine. temperature, then shut off the engine.
Disconnect the pressure and return lines at the steering gear and allow Disconnect the pressure and return lines at the steering gear and allow
the power steering reservoir and hoses to drain into a suitable the power steering reservoir and hoses to drain into a suitable
container. container.
Jack up the front end of the vehicle so the wheels can be steered Jack up the front end of the vehicle so the wheels can be steered
manually. Steer several times from left to right steering stops to pump manually. Steer several times from left to right steering stops to pump
the remaining fluid out of the system. the remaining fluid out of the system.
Replace the steering system filter element. Before reinstalling the Replace the steering system filter element. Before reinstalling the
element, clean the inside of the reservoir with a clean cloth. Reconnect element, clean the inside of the reservoir with a clean cloth. Reconnect
the pressure and return lines, then refill the reservoir with the the pressure and return lines, then refill the reservoir with the
recommended fluid. Refer to the label on the side of the reservoir for recommended fluid. Refer to the label on the side of the reservoir for
156 156
STEERING GEAR BLEED PROCEDURES — TRW 92 SERIES STEERING GEAR BLEED PROCEDURES — TRW 92 SERIES
STEERING GEARS STEERING GEARS
For chassis equipped with TRW 92 series steering gears (i.e., 392, For chassis equipped with TRW 92 series steering gears (i.e., 392,
492, etc.), bleed air from the steering system by lowering the chassis to 492, etc.), bleed air from the steering system by lowering the chassis to
the ground, starting the engine and steering the wheels several times the ground, starting the engine and steering the wheels several times
from left to right steering stops. from left to right steering stops.
Make sure the reservoir does not run dry during the Make sure the reservoir does not run dry during the
purging operation as air may be drawn into the purging operation as air may be drawn into the
system. system.
STEERING GEAR BLEED PROCEDURES — SHEPPARD M90 AND STEERING GEAR BLEED PROCEDURES — SHEPPARD M90 AND
M100 STEERING GEARS M100 STEERING GEARS
For chassis equipped with Sheppard M90 or M100 steering gears, For chassis equipped with Sheppard M90 or M100 steering gears,
bleed air from the system as follows: bleed air from the system as follows:
Beginning approximately August 2002, an auto-bleed Beginning approximately August 2002, an auto-bleed
feature was incorporated into Sheppard M90 and feature was incorporated into Sheppard M90 and
M100 steering gears. To bleed the air from these M100 steering gears. To bleed the air from these
steering gears, it is only necessary to start the engine steering gears, it is only necessary to start the engine
and fully steer the wheels several times from the left to and fully steer the wheels several times from the left to
right steering stops. For Sheppard steering gears right steering stops. For Sheppard steering gears
without the auto-bleed feature, it is VERY IMPORTANT without the auto-bleed feature, it is VERY IMPORTANT
that the steering gear be bled as described in the that the steering gear be bled as described in the
following procedures. Manual-bleed M90, M100 and following procedures. Manual-bleed M90, M100 and
M110 steering gears are identified by the bleeder M110 steering gears are identified by the bleeder
screw located in the steering gear housing, above the screw located in the steering gear housing, above the
pitman arm shaft. Steering gears with the auto-bleed pitman arm shaft. Steering gears with the auto-bleed
feature will not have a bleeder screw, and can also be feature will not have a bleeder screw, and can also be
identified by the word “Auto” cast into the housing. identified by the word “Auto” cast into the housing.
157 157
1. With the wheels on the ground, start the engine and turn the 1. With the wheels on the ground, start the engine and turn the
steering wheel to a full left turn. steering wheel to a full left turn.
2. Locate the bleeder screw in the steering gear. The bleeder screw 2. Locate the bleeder screw in the steering gear. The bleeder screw
is located in the steering gear housing, above the pitman arm is located in the steering gear housing, above the pitman arm
shaft. shaft.
40 40
Figure 40 — Sheppard M90 Steering Gear Bleeder Screw Location Figure 40 — Sheppard M90 Steering Gear Bleeder Screw Location
158 158
3. Using a 1/8″ Allen wrench, open the bleeder screw 2–3 turns. 3. Using a 1/8″ Allen wrench, open the bleeder screw 2–3 turns.
4. Turn the steering wheel to a full right turn. 4. Turn the steering wheel to a full right turn.
5. Close the bleeder screw when the wheels are turned fully to the 5. Close the bleeder screw when the wheels are turned fully to the
right. right.
Turning the wheels to a full right turn with the bleeder Turning the wheels to a full right turn with the bleeder
screw open forces air under pressure from the system. screw open forces air under pressure from the system.
DO NOT steer the wheels to the left with the bleeder DO NOT steer the wheels to the left with the bleeder
screw open as this will draw air back into the system. screw open as this will draw air back into the system.
6. Repeat the above procedures 2–3 times until a smooth stream of 6. Repeat the above procedures 2–3 times until a smooth stream of
oil flows from the bleeder screw. A smooth stream of oil indicates oil flows from the bleeder screw. A smooth stream of oil indicates
that all the air has been purged from the system. that all the air has been purged from the system.
Make sure the reservoir does not run dry during the Make sure the reservoir does not run dry during the
purging operation as air may be drawn into the purging operation as air may be drawn into the
system. system.
159 159
Geared Components (Transmission and Carriers) Geared Components (Transmission and Carriers)
Add oil or drain and refill while units are hot. Fill to level of filler plug Add oil or drain and refill while units are hot. Fill to level of filler plug
hole. DO NOT overfill. See “LUBRICANT SPECIFICATIONS” on page hole. DO NOT overfill. See “LUBRICANT SPECIFICATIONS” on page
267. 267.
When the oil level in any geared unit (transmission, carrier, etc.) is When the oil level in any geared unit (transmission, carrier, etc.) is
checked, oil must either be seen or felt to be level with the filler plug checked, oil must either be seen or felt to be level with the filler plug
hole. If oil can only be felt by reaching the finger down into the unit, the hole. If oil can only be felt by reaching the finger down into the unit, the
oil level is insufficient. oil level is insufficient.
41 41
Figure 41 — Oil Level Check Figure 41 — Oil Level Check
Take care not to burn hands when checking oil Take care not to burn hands when checking oil
level on hot geared units. level on hot geared units.
160 160
Transmissions Transmissions
Remove and clean the magnetic drain plug and the magnetic oil filter Remove and clean the magnetic drain plug and the magnetic oil filter
plug (if equipped). Also clean the trough located inside the area from plug (if equipped). Also clean the trough located inside the area from
where the magnetic filter plug was removed. After the oil has drained, where the magnetic filter plug was removed. After the oil has drained,
reinstall the plugs. Remove the fill plug and fill the transmission with reinstall the plugs. Remove the fill plug and fill the transmission with
enough of the recommended lubricant (see “LUBRICANT enough of the recommended lubricant (see “LUBRICANT
SPECIFICATIONS” on page 267) to bring the level to the bottom of the SPECIFICATIONS” on page 267) to bring the level to the bottom of the
filler plug hole. Reinstall the filler plug. filler plug hole. Reinstall the filler plug.
Remove the breather(s). Clean with a suitable, nonflammable solvent; Remove the breather(s). Clean with a suitable, nonflammable solvent;
check for obstructions, and reinstall. check for obstructions, and reinstall.
42 42
Figure 42 — Fill Plug, Drain Plug, Magnetic Filter Plug and Breather Figure 42 — Fill Plug, Drain Plug, Magnetic Filter Plug and Breather
Locations Locations
Do not overtighten the fill plug. Tighten the fill plug as follows: Do not overtighten the fill plug. Tighten the fill plug as follows:
앫 Tapered pipe plug finger-tighten first, then tighten an additional 앫 Tapered pipe plug finger-tighten first, then tighten an additional
3/4 to 1 turn (not to exceed 75 N•m [55 lb-ft]) with a wrench. 3/4 to 1 turn (not to exceed 75 N•m [55 lb-ft]) with a wrench.
앫 O-ring boss-style plug tighten to 41–48 N•m (30–35 lb-ft). 앫 O-ring boss-style plug tighten to 41–48 N•m (30–35 lb-ft).
DO NOT exceed 48 N•m (35 lb-ft) as the plug can DO NOT exceed 48 N•m (35 lb-ft) as the plug can
seize, resulting in damage to the transmission case seize, resulting in damage to the transmission case
when attempting to remove the plug at a later time. when attempting to remove the plug at a later time.
161 161
Range Shift Valve Filter (Range Shifted Transmissions) Range Shift Valve Filter (Range Shifted Transmissions)
At each C and D inspection interval, remove and clean or replace the At each C and D inspection interval, remove and clean or replace the
range shift valve filter as follows: range shift valve filter as follows:
43 43
Figure 43 — Range Shift Valve Cover Spring and Filter Figure 43 — Range Shift Valve Cover Spring and Filter
1. Filter 3. Filter O-Ring 1. Filter 3. Filter O-Ring

2. Valve Housing 2. Valve Housing
1. Remove the four top cover screws from the valve. 1. Remove the four top cover screws from the valve.
2. Separate the cover from the valve housing. 2. Separate the cover from the valve housing.
3. Remove the filter and filter O-ring. 3. Remove the filter and filter O-ring.
4. Clean (or replace, if necessary) the filter with a suitable, non- 4. Clean (or replace, if necessary) the filter with a suitable, non-
flammable solvent, then dry the filter with clean, dry compressed flammable solvent, then dry the filter with clean, dry compressed
air. air.
5. Apply Mobile Grease No. 28 sparingly to the filter O-ring. 5. Apply Mobile Grease No. 28 sparingly to the filter O-ring.
162 162
Do not over-lubricate the O-ring, as this may result in Do not over-lubricate the O-ring, as this may result in
filter restriction. Make sure that the O-ring is only filter restriction. Make sure that the O-ring is only
lightly lubricated. lightly lubricated.
6. Install the O-ring and the filter into the filter bore of the housing. 6. Install the O-ring and the filter into the filter bore of the housing.
Set the filter on top of the O-ring and make sure the O-ring is Set the filter on top of the O-ring and make sure the O-ring is
properly seated. properly seated.
7. Apply Mobile Grease No. 28 sparingly to the top cover seal, then 7. Apply Mobile Grease No. 28 sparingly to the top cover seal, then
install the seal into the groove in the top cover, making sure all install the seal into the groove in the top cover, making sure all
portions of the seal are properly located. (If the top cover seal is portions of the seal are properly located. (If the top cover seal is
damaged in any way, it must be replaced.) damaged in any way, it must be replaced.)
8. Install the top cover and the four cover screws. Tighten the 8. Install the top cover and the four cover screws. Tighten the
screws to 3.4–4.5 N•m (30–40 lb-in). screws to 3.4–4.5 N•m (30–40 lb-in).
Eaton Fuller Transmissions Eaton Fuller Transmissions

The transmission oil fill plug used on Eaton Fuller transmissions The transmission oil fill plug used on Eaton Fuller transmissions
incorporates an O-ring seal. This plug requires the use of a 1/2-inch incorporates an O-ring seal. This plug requires the use of a 1/2-inch
internal square drive tool for removal and reinstallation. Thread sealant internal square drive tool for removal and reinstallation. Thread sealant
is not required when installing the plug, and the plug must be tightened is not required when installing the plug, and the plug must be tightened
to 57 N폷m (42 lb-ft). to 57 N폷m (42 lb-ft).
163 163
Transfer Case Transfer Case

With the transfer case at operating temperature, remove the magnetic With the transfer case at operating temperature, remove the magnetic
drain plug and drain the oil. Clean and reinstall the plug. Remove the drain plug and drain the oil. Clean and reinstall the plug. Remove the
breather, clean with a suitable, nonflammable solvent, check for breather, clean with a suitable, nonflammable solvent, check for
obstructions, and reinstall. Remove the filler plug and fill the transfer obstructions, and reinstall. Remove the filler plug and fill the transfer
case with enough of the recommended oil to bring the level to the case with enough of the recommended oil to bring the level to the
bottom of the filler plug hole. Reinstall the filler plug. bottom of the filler plug hole. Reinstall the filler plug.
44 44
Figure 44 — Transfer Case Figure 44 — Transfer Case
On transfer cases equipped with an optional PTO, On transfer cases equipped with an optional PTO,
change the oil filter when the oil is changed. The change the oil filter when the oil is changed. The
transfer case shown in the illustration above is transfer case shown in the illustration above is
equipped with an optional PTO. Transfer cases that equipped with an optional PTO. Transfer cases that
are not equipped with a PTO do not have an oil filter, are not equipped with a PTO do not have an oil filter,
and have a shorter hose that runs from the main shaft and have a shorter hose that runs from the main shaft
cover to the countershaft cover. cover to the countershaft cover.
164 164
Rear Engine Power Take-Off (REPTO) Rear Engine Power Take-Off (REPTO)
The REPTO unit is lubricated by oil from the engine. Scheduled engine The REPTO unit is lubricated by oil from the engine. Scheduled engine
oil changes take care of any periodic service requirements. oil changes take care of any periodic service requirements.
Transmission, Auxiliary Transmission, Transfer Case Transmission, Auxiliary Transmission, Transfer Case
Linkages Linkages
At each oil change interval, put two drops of engine oil on the movable At each oil change interval, put two drops of engine oil on the movable
connections of the linkages for the transmission, auxiliary transmission connections of the linkages for the transmission, auxiliary transmission
and transfer case. and transfer case.
Rear Axles Rear Axles

Add oil or drain and refill while axles are hot. Fill to the level of the filler Add oil or drain and refill while axles are hot. Fill to the level of the filler
plug hole. DO NOT overfill. See “Gear Oils” on page 268. plug hole. DO NOT overfill. See “Gear Oils” on page 268.
Rear axles with front-mounted carriers — With the axle at operating Rear axles with front-mounted carriers — With the axle at operating
temperature, remove the magnetic drain plug and drain the oil from the temperature, remove the magnetic drain plug and drain the oil from the
axle housing. Clean and reinstall the plug. Remove the filler plug and axle housing. Clean and reinstall the plug. Remove the filler plug and
fill the axle housing with enough of the recommended oil to bring the fill the axle housing with enough of the recommended oil to bring the
level to the bottom of the filler plug hole. Reinstall the plug. level to the bottom of the filler plug hole. Reinstall the plug.
Rear axles with top-mounted carriers — With the axle(s) at Rear axles with top-mounted carriers — With the axle(s) at
operating temperature, remove the magnetic drain plugs from the operating temperature, remove the magnetic drain plugs from the
interaxle power divider on the front carrier (if so equipped), the carrier interaxle power divider on the front carrier (if so equipped), the carrier
bevel gear compartment(s), and the axle housing(s), and allow the oil bevel gear compartment(s), and the axle housing(s), and allow the oil
to drain. Clean and reinstall the plugs. Refer to “Magnetic Strips and Oil to drain. Clean and reinstall the plugs. Refer to “Magnetic Strips and Oil
Troughs” on page 167 for information concerning the magnetic strips Troughs” on page 167 for information concerning the magnetic strips
and oil trough cleaning procedures. Remove the filler plug from the and oil trough cleaning procedures. Remove the filler plug from the
interaxle power divider (if equipped) and add one pint (1.5 pints for interaxle power divider (if equipped) and add one pint (1.5 pints for
CRD200 carriers) of the recommended oil. Reinstall the filler plug. CRD200 carriers) of the recommended oil. Reinstall the filler plug.
Remove the filler plugs from the bevel gear compartment(s) and fill with Remove the filler plugs from the bevel gear compartment(s) and fill with
the recommended oil until level with the bottom of the filler plug hole. the recommended oil until level with the bottom of the filler plug hole.
Reinstall the filler plug(s). Remove the filler plugs from the axle Reinstall the filler plug(s). Remove the filler plugs from the axle
housing(s) and fill with enough of the recommended oil until level with housing(s) and fill with enough of the recommended oil until level with
the bottom of the filler plug hole. Reinstall the filler plug(s). If the axle is the bottom of the filler plug hole. Reinstall the filler plug(s). If the axle is
equipped with an elbow fitting in the axle housing fill plug hole, the equipped with an elbow fitting in the axle housing fill plug hole, the
easiest method of filling the housing is by removing the breather fitting easiest method of filling the housing is by removing the breather fitting
from the right-hand side of the carrier and the fill plug from the elbow from the right-hand side of the carrier and the fill plug from the elbow
fitting. Fill the housing through the breather hole until the oil runs out fitting. Fill the housing through the breather hole until the oil runs out
the elbow fitting. Reinstall the fill plug and the breather fitting. the elbow fitting. Reinstall the fill plug and the breather fitting.
165 165
45 45
Figure 45 — Filler and Drain Plug Locations Figure 45 — Filler and Drain Plug Locations
When checking oil level in rear axles having top-mounted carriers, When checking oil level in rear axles having top-mounted carriers,
check after the vehicle has been operated, the oil is hot and the check after the vehicle has been operated, the oil is hot and the
chassis is parked on level ground. Check the oil level by removing the chassis is parked on level ground. Check the oil level by removing the
fill/level plugs from the axle housings and the bevel gear fill/level plugs from the axle housings and the bevel gear
compartments. The level is correct when oil runs out of the fill plug hole compartments. The level is correct when oil runs out of the fill plug hole
in the axle housing, and slightly below the fill plug hole in the bevel in the axle housing, and slightly below the fill plug hole in the bevel
gear compartment. On axle housings with an elbow fitting in the axle gear compartment. On axle housings with an elbow fitting in the axle
housing fill plug hole, oil level must be to the top of the elbow fitting. If housing fill plug hole, oil level must be to the top of the elbow fitting. If
the level in the axle housing is low, add oil to the axle housing and the the level in the axle housing is low, add oil to the axle housing and the
bevel gear compartment until level with the bottom of the fill plug holes. bevel gear compartment until level with the bottom of the fill plug holes.
DO NOT add oil if the level in the axle housing is sufficient. Reinstall DO NOT add oil if the level in the axle housing is sufficient. Reinstall
the plugs. the plugs.
It is not necessary to check oil level in the interaxle It is not necessary to check oil level in the interaxle
power divider. If oil level in the carrier is sufficient, level power divider. If oil level in the carrier is sufficient, level
in the interaxle power divider will also be sufficient. in the interaxle power divider will also be sufficient.
166 166
Interwheel Power Divider Interwheel Power Divider

For rear axles equipped with interwheel power dividers, a friction- For rear axles equipped with interwheel power dividers, a friction-
modifier additive, Bulldog Power Divider Top Treat (part modifier additive, Bulldog Power Divider Top Treat (part
No. 9853-PDT1), is available to prevent power divider snapping or No. 9853-PDT1), is available to prevent power divider snapping or
binding. If power divider snapping or binding is experienced, this binding. If power divider snapping or binding is experienced, this
additive should be added at each rear axle gear oil change. One additive should be added at each rear axle gear oil change. One
container (20 fl.oz.) is required for each carrier. Bulldog Power Divider container (20 fl.oz.) is required for each carrier. Bulldog Power Divider
Top Treat is available from your local MACK dealer. Top Treat is available from your local MACK dealer.
Magnetic Strips and Oil Troughs Magnetic Strips and Oil Troughs
An oil trough with magnetic strips is attached to the inside of the bevel An oil trough with magnetic strips is attached to the inside of the bevel
gear compartment cover. The outside of the cover contains the notice gear compartment cover. The outside of the cover contains the notice
“Internal Magnetic Strips and Oil Trough Require Periodic Cleaning.” “Internal Magnetic Strips and Oil Trough Require Periodic Cleaning.”
Clean the oil trough and magnetic strips each time the oil is changed or Clean the oil trough and magnetic strips each time the oil is changed or
when the cover is removed. when the cover is removed.
46 46
Figure 46 — Magnetic Strips and Oil Trough Figure 46 — Magnetic Strips and Oil Trough
Whenever the cover is removed from the bevel gear Whenever the cover is removed from the bevel gear
compartment, check the cover mating surface. If signs compartment, check the cover mating surface. If signs
of corrosion or erosion are evident, the cover must be of corrosion or erosion are evident, the cover must be
replaced. replaced.
167 167
Carrier Housing Breathers Carrier Housing Breathers

Remove the carrier housing breather(s) each time the rear axle(s) oil is Remove the carrier housing breather(s) each time the rear axle(s) oil is
changed. Clean the breather(s) in a suitable, nonflammable solvent changed. Clean the breather(s) in a suitable, nonflammable solvent
and check for obstructions. Blow dry with compressed air, then and check for obstructions. Blow dry with compressed air, then
reinstall. reinstall.
47 47
Figure 47 — Carrier Housing Breathers Figure 47 — Carrier Housing Breathers
Wheel Bearing Lubrication Wheel Bearing Lubrication

The wheel bearings on standard MACK front non-driving axles may be The wheel bearings on standard MACK front non-driving axles may be
either oil-lubricated, grease-lubricated or semi-fluid grease-lubricated. either oil-lubricated, grease-lubricated or semi-fluid grease-lubricated.
168 168
OIL-LUBRICATED FRONT WHEEL BEARINGS OIL-LUBRICATED FRONT WHEEL BEARINGS

Front axles having oil-lubricated wheel bearings are identified by the Front axles having oil-lubricated wheel bearings are identified by the
transparent plastic hubcap which is inscribed with a mark to indicate transparent plastic hubcap which is inscribed with a mark to indicate
the proper oil level. The cap in the center of the transparent window the proper oil level. The cap in the center of the transparent window
can be removed when it becomes necessary to add oil. Check the oil can be removed when it becomes necessary to add oil. Check the oil
level regularly, at the daily pre-trip inspection. Add the recommended level regularly, at the daily pre-trip inspection. Add the recommended
oil (refer to “Gear Oils” on page 268) when necessary. Oil-lubricated oil (refer to “Gear Oils” on page 268) when necessary. Oil-lubricated
front wheel bearings must be removed, cleaned and inspected at each front wheel bearings must be removed, cleaned and inspected at each
D inspection interval. D inspection interval.
48 48
Figure 48 — Front Axle Hub Figure 48 — Front Axle Hub
169 169
GREASE-LUBRICATED FRONT WHEEL BEARINGS GREASE-LUBRICATED FRONT WHEEL BEARINGS

The hubcap on front axles having grease-lubricated front wheel The hubcap on front axles having grease-lubricated front wheel
bearings may be either a metal cap or a transparent window. bearings may be either a metal cap or a transparent window.
Grease-lubricated wheel bearings must be removed, cleaned and Grease-lubricated wheel bearings must be removed, cleaned and
repacked with grease at each D inspection interval. repacked with grease at each D inspection interval.
SEMI-FLUID GREASE-LUBRICATED FRONT WHEEL BEARINGS SEMI-FLUID GREASE-LUBRICATED FRONT WHEEL BEARINGS
Front axles with semi-fluid grease-lubricated wheel bearings also have Front axles with semi-fluid grease-lubricated wheel bearings also have
a hubcap with a transparent window and a vent cap in the center. The a hubcap with a transparent window and a vent cap in the center. The
center vent cap is not to be removed to add oil to the hub assembly. center vent cap is not to be removed to add oil to the hub assembly.
Semi-fluid grease-lubricated wheel bearings must be removed, Semi-fluid grease-lubricated wheel bearings must be removed,
cleaned and re-lubricated at each D inspection interval. cleaned and re-lubricated at each D inspection interval.
UNITIZED WHEEL HUBS UNITIZED WHEEL HUBS

Unitized wheel hubs (with pre-set wheel bearings) are sealed and Unitized wheel hubs (with pre-set wheel bearings) are sealed and
lubricated for life. Disassembly of the hub to clean and lubricate the lubricated for life. Disassembly of the hub to clean and lubricate the
wheel bearings is not necessary, and doing so may void the wheel bearings is not necessary, and doing so may void the
manufacturer’s warranty. Additionally, wheel bearing adjustments are manufacturer’s warranty. Additionally, wheel bearing adjustments are
not necessary with unitized hubs. Consult the wheel hub not necessary with unitized hubs. Consult the wheel hub
manufacturer’s service literature for additional service information. manufacturer’s service literature for additional service information.
For ArvinMeritor™ unitized hub assemblies, the following inspections For ArvinMeritor™ unitized hub assemblies, the following inspections
must be performed at the intervals listed below: must be performed at the intervals listed below:
Detailed Inspection Detailed Inspection

앫 After the initial 321 800 km (200,000 miles) of operation. 앫 After the initial 321 800 km (200,000 miles) of operation.
앫 After every additional 321 800 km (200,000 miles) of operation 앫 After every additional 321 800 km (200,000 miles) of operation
thereafter. thereafter.
Basic Inspection Basic Inspection

앫 At each 80 467 km (50,000 mile) interval following the initial 앫 At each 80 467 km (50,000 mile) interval following the initial
321 800 km (200,000 miles) of operation or at the most frequent 321 800 km (200,000 miles) of operation or at the most frequent
preventive maintenance interval (C and D Inspections). preventive maintenance interval (C and D Inspections).
170 170
For detailed instructions on performing the Detailed and Basic For detailed instructions on performing the Detailed and Basic
Inspections, refer to the ArvinMeritor™ service publication, Inspections, refer to the ArvinMeritor™ service publication,
Maintenance Manual 2, Front Non-driving Steering Axles. This manual Maintenance Manual 2, Front Non-driving Steering Axles. This manual
can be obtained by visiting Literature on Demand on the ArvinMeritor can be obtained by visiting Literature on Demand on the ArvinMeritor
web site at www.meritorhvs.com. web site at www.meritorhvs.com.
FRONT DRIVING AXLES FRONT DRIVING AXLES

Wheel bearings on front driving axles may be oil- or grease-lubricated. Wheel bearings on front driving axles may be oil- or grease-lubricated.
Consult the specific axle manufacturer’s service publications for Consult the specific axle manufacturer’s service publications for
lubrication recommendations, specifications and procedures. lubrication recommendations, specifications and procedures.
REAR WHEEL BEARINGS REAR WHEEL BEARINGS

Rear wheel bearings are lubricated by oil from the carrier and require Rear wheel bearings are lubricated by oil from the carrier and require
no periodic inspection of lubricant level at the wheel bearings. Rear no periodic inspection of lubricant level at the wheel bearings. Rear
wheel bearings must be removed, cleaned and inspected at each D wheel bearings must be removed, cleaned and inspected at each D
inspection interval. inspection interval.
KING PIN UPPER BEARING LU182BRICATION KING PIN UPPER BEARING LU182BRICATION
Lubricate the upper king pin bearing with the vehicle on the ground. Lubricate the upper king pin bearing with the vehicle on the ground.
Apply MG-C grease to the upper bearing grease fitting until grease Apply MG-C grease to the upper bearing grease fitting until grease
purges from the joint between the upper steering knuckle and the purges from the joint between the upper steering knuckle and the
upper portion of the axle eyelet. upper portion of the axle eyelet.
The upper king pin cover on MACK FXL18 and FXL20 The upper king pin cover on MACK FXL18 and FXL20
front axles has two grease fittings. It is only necessary front axles has two grease fittings. It is only necessary
to apply grease to one of the fittings. to apply grease to one of the fittings.
KING PIN LOWER BEARING LUBRICATION KING PIN LOWER BEARING LUBRICATION
Lubricate the king pin lower bearing with the front of the vehicle raised Lubricate the king pin lower bearing with the front of the vehicle raised
off the ground and supported on jackstands of adequate capacity to off the ground and supported on jackstands of adequate capacity to
support the weight of the vehicle. Apply MG-C grease to the lower support the weight of the vehicle. Apply MG-C grease to the lower
bushing grease fitting until grease purges from the joint between the bushing grease fitting until grease purges from the joint between the
lower steering knuckle and the lower portion of the axle eyelet. lower steering knuckle and the lower portion of the axle eyelet.
171 171
Lubrication Chart Lubrication Chart

49 49
Figure 49 — Mack Chassis Lubrication Chart Figure 49 — Mack Chassis Lubrication Chart
172 172
50 50

Figure 50 — A–C Key References Figure 50 — A–C Key References
173 173
51 51
Figure 51 — D–H Key References Figure 51 — D–H Key References
174 174
52 52
Figure 52 — I–K Key References Figure 52 — I–K Key References
175 175
53 53

Figure 53 — L–N Key References Figure 53 — L–N Key References
176 176
54 54

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&'" %
(&!&!"!"'%$(%(%'"! (&!&!"!"'%$(%(%'"!
(%'(##%!(#!%!&*')"!%"(!"*%#!(&! (%'(##%!(#!%!&*')"!%"(!"*%#!(&!
*')%& *')%&
- !&'%!%&##+ '"'''!"!''%(!!"!&"'&'%!% - !&'%!%&##+ '"'''!"!''%(!!"!&"'&'%!%
!%'"('#('&'&!'+#%&(!"!+ !%'"('#('&'&!'+#%&(!"!+
-- ")!&#'"!")%'"&&%&%!%&''! -- ")!&#'"!")%'"&&%&%!%&''!

Figure 54 — O–R Key References Figure 54 — O–R Key References
177 177
55 55

Figure 55 — S–T Key References Figure 55 — S–T Key References
178 178
STEERING KNUCKLE INSPECTION STEERING KNUCKLE INSPECTION
STEERING KNUCKLE INSPECTION STEERING KNUCKLE INSPECTION

At each C and D inspection interval, steam clean and inspect each At each C and D inspection interval, steam clean and inspect each
steering knuckle for cracks. Pay particular attention to the areas of the steering knuckle for cracks. Pay particular attention to the areas of the
steering lever boss, cross-steering tube boss and the king pin lower steering lever boss, cross-steering tube boss and the king pin lower
boss. If cracks are noticed, consult your local MACK dealer. boss. If cracks are noticed, consult your local MACK dealer.
56 56

Figure 56 — Inspect Steering Knuckle Figure 56 — Inspect Steering Knuckle
1. Steering Lever Boss 3. King Pin Lower Boss 1. Steering Lever Boss 3. King Pin Lower Boss
2. Cross-Steering Tube Boss 2. Cross-Steering Tube Boss
179 179
CARRIER CAPSCREW TORQUE CARRIER CAPSCREW TORQUE

At each C and D inspection interval, check and adjust the torque of the At each C and D inspection interval, check and adjust the torque of the
capscrews that secure the top-mounted carrier to the axle housing. On capscrews that secure the top-mounted carrier to the axle housing. On
certain carrier assemblies, two of the capscrews are located inside the certain carrier assemblies, two of the capscrews are located inside the
bevel gear compartment where they are not visible. bevel gear compartment where they are not visible.
57 57
Figure 57 — Carrier Capscrews Figure 57 — Carrier Capscrews
The following carrier assemblies have capscrews located inside the The following carrier assemblies have capscrews located inside the
bevel gear compartment: bevel gear compartment:
CRD(L)92(1), CRDLP92(1), CRDPC92(1), CRD(L)93(1), CRD112, CRD(L)92(1), CRDLP92(1), CRDPC92(1), CRD(L)93(1), CRD112,
CRDPC112(1), CRD113(1), CRDP95(1), CRD96(1), CRD200 CRDPC112(1), CRD113(1), CRDP95(1), CRD96(1), CRD200
To gain access to these “hidden” capscrews, drain the bevel gear To gain access to these “hidden” capscrews, drain the bevel gear
compartment, and remove the cover. After checking the torque (refer to compartment, and remove the cover. After checking the torque (refer to
table on page 181), reinstall the cover and fill the bevel gear table on page 181), reinstall the cover and fill the bevel gear
compartment with enough of the recommended oil to bring the level to compartment with enough of the recommended oil to bring the level to
the bottom of the filler plug hole. (See “Gear Oils” on page 268.) the bottom of the filler plug hole. (See “Gear Oils” on page 268.)
Whenever the cover is removed from the bevel gear Whenever the cover is removed from the bevel gear
compartment, check the cover mating surface. If signs compartment, check the cover mating surface. If signs
of corrosion or erosion are evident, the cover must be of corrosion or erosion are evident, the cover must be
replaced. replaced.
180 180
CAPSCREW TORQUE SPECIFICATIONS CAPSCREW TORQUE SPECIFICATIONS
Carrier Torque N•m (Lb-ft) Carrier Torque N•m (Lb-ft)
92/93 Series 179–201 (132–148) 92/93 Series 179–201 (132–148)
112/113 Series 179–201 (132–148) 112/113 Series 179–201 (132–148)
95/96 Series 645–716 (476–528) 95/96 Series 645–716 (476–528)
200 Series 179–201 (132–148) 200 Series 179–201 (132–148)
181 181
FRONT AXLE STATIC SHAKE TEST FRONT AXLE STATIC SHAKE TEST
FRONT AXLE STATIC SHAKE TEST FRONT AXLE STATIC SHAKE TEST
At each A, B, C and D inspection interval, perform a static shake test to At each A, B, C and D inspection interval, perform a static shake test to
check for looseness in the front axle springs and the steering system. check for looseness in the front axle springs and the steering system.
To perform this test, apply the parking brakes and run the engine at an To perform this test, apply the parking brakes and run the engine at an
idle. With an assistant moving the steering wheel back and forth, check idle. With an assistant moving the steering wheel back and forth, check
the front springs for looseness at the attachment points. Any movement the front springs for looseness at the attachment points. Any movement
of the spring indicates that the spring leaf may be broken, possibly at of the spring indicates that the spring leaf may be broken, possibly at
the spring eye wrapper, or the bronze bushing may be worn. If the spring eye wrapper, or the bronze bushing may be worn. If
movement is detected, clean and inspect the spring leaf, wrapper and movement is detected, clean and inspect the spring leaf, wrapper and
bronze bushing. Worn bushings must be replaced. If the spring bronze bushing. Worn bushings must be replaced. If the spring
wrapper is broken, the spring leaf must be replaced. wrapper is broken, the spring leaf must be replaced.
58 58
Figure 58 — Spring Eye Wrapper Figure 58 — Spring Eye Wrapper
1. Check this area of spring wrapper leaf for potential cracks. 1. Check this area of spring wrapper leaf for potential cracks.
While performing the shake test, also check the complete steering While performing the shake test, also check the complete steering
system (i.e., steering gear mounting, pitman arm, drag link, cross system (i.e., steering gear mounting, pitman arm, drag link, cross
steering tube, steering levers, etc.) for looseness. If any looseness is steering tube, steering levers, etc.) for looseness. If any looseness is
seen in the steering system, the cause must be investigated and seen in the steering system, the cause must be investigated and
corrected. corrected.
182 182
SPRING CLIP (U-BOLT) TORQUE SPRING CLIP (U-BOLT) TORQUE
Proper spring clip torque must be maintained for Proper spring clip torque must be maintained for
safe operation of the vehicle. Loose or improperly safe operation of the vehicle. Loose or improperly
torqued spring clips may adversely affect the torqued spring clips may adversely affect the
driver’s steering control of the vehicle. driver’s steering control of the vehicle.
Always use an accurately calibrated torque wrench to Always use an accurately calibrated torque wrench to
torque the spring clips. torque the spring clips.
After any repair operation that involved the removal After any repair operation that involved the removal
and reinstallation of a spring, the spring clips must be and reinstallation of a spring, the spring clips must be
retorqued after a minimum of one day and a maximum retorqued after a minimum of one day and a maximum
of one week or 5 000 km/3,000 miles of service. of one week or 5 000 km/3,000 miles of service.
183 183
MACK Tandem Suspensions MACK Tandem Suspensions

Spring clips must be retorqued during the first 5 000 km/3,000 miles or Spring clips must be retorqued during the first 5 000 km/3,000 miles or
3–4 months (whichever comes first). After the initial break-in period, 3–4 months (whichever comes first). After the initial break-in period,
retorque the spring clips at every C and D inspection interval. retorque the spring clips at every C and D inspection interval.
ST34 and ST38 suspensions do not require retorquing at the end of ST34 and ST38 suspensions do not require retorquing at the end of
the initial break-in period. Retorque these spring clips at every C and D the initial break-in period. Retorque these spring clips at every C and D
inspection. inspection.
Vendor Tandem Suspensions Vendor Tandem Suspensions
Hendrickson Retorque spring clips at C and D inspection Hendrickson Retorque spring clips at C and D inspection
intervals per vendor specifications. intervals per vendor specifications.
Neway Retorque all fasteners in the suspension and Neway Retorque all fasteners in the suspension and
the frame brackets at first 5 000 km/ the frame brackets at first 5 000 km/
3,000 miles and thereafter at C and D 3,000 miles and thereafter at C and D
inspection intervals per vendor specifications. inspection intervals per vendor specifications.
Reyco Retorque spring clips and equalizer nuts at Reyco Retorque spring clips and equalizer nuts at
first 1 600 km/1,000 miles per vendor first 1 600 km/1,000 miles per vendor
specifications. At B, C and D inspection specifications. At B, C and D inspection
intervals, retorque spring clips, equalizer intervals, retorque spring clips, equalizer
nuts, torque arm bolts (at hangers and axle nuts, torque arm bolts (at hangers and axle
seats), and torque arm tube clamp nuts per seats), and torque arm tube clamp nuts per
vendor specifications. vendor specifications.
184 184
Front (Steering) Axle and Single Rear Axle Front (Steering) Axle and Single Rear Axle
Retorque the spring clips on the front (steering) axle and the single Retorque the spring clips on the front (steering) axle and the single
rear axle at the first 5 000 km/3,000 miles, and thereafter at every C rear axle at the first 5 000 km/3,000 miles, and thereafter at every C
and D inspection interval. and D inspection interval.
SPRING CLIP NUT TORQUE CHART (FRONT AND REAR AXLES) SPRING CLIP NUT TORQUE CHART (FRONT AND REAR AXLES)
Spring Clip Nut Torque N폷m Spring Clip Nut Torque N폷m
Spring Clip Diameter mm [Inches] (Lb-ft) Spring Clip Diameter mm [Inches] (Lb-ft)
15.9 [0.625 (5/8)] 271–305 (200–225) 15.9 [0.625 (5/8)] 271–305 (200–225)
19.0 [0.750 (3/4)] 434–461 (320–340) 19.0 [0.750 (3/4)] 434–461 (320–340)
22.2 [0.875 (7/8)] with flat top 542–610 (400–450) 22.2 [0.875 (7/8)] with flat top 542–610 (400–450)
22.2 [0.875 (7/8)] with circular top 678–746 (500–550) 22.2 [0.875 (7/8)] with circular top 678–746 (500–550)
25.4 [1.000 (1)] 1085–1193 (800–880) 25.4 [1.000 (1)] 1085–1193 (800–880)
28.6 [1.125 (1-1/8)] 1423–1558 (1050–1150) 28.6 [1.125 (1-1/8)] 1423–1558 (1050–1150)
31.8 [1.250 (1-1/4)] 1897–2033 (1400–1500) 31.8 [1.250 (1-1/4)] 1897–2033 (1400–1500)
185 185
Spring Clip (U-Bolt) Torque Procedure Spring Clip (U-Bolt) Torque Procedure
When installing spring clip nuts on either the front or rear springs, the When installing spring clip nuts on either the front or rear springs, the
spring clip threads must first be lubricated with NEVER-SIEZE™. spring clip threads must first be lubricated with NEVER-SIEZE™.
NEVER-SIEZE™ must also be applied to the special washers, if so NEVER-SIEZE™ must also be applied to the special washers, if so
equipped, to remove the frictional drag on the nuts. Use the following equipped, to remove the frictional drag on the nuts. Use the following
recommended tightening sequence to torque the spring clips. Torque recommended tightening sequence to torque the spring clips. Torque
requirements are the same for either type of lubricant. requirements are the same for either type of lubricant.
1. Tighten all spring clips until they are snug. 1. Tighten all spring clips until they are snug.
2. Tighten nuts, using the sequence shown below, to approximately 2. Tighten nuts, using the sequence shown below, to approximately
one third of the recommended torque. Refer to table on page 185 one third of the recommended torque. Refer to table on page 185
for proper torque requirements. for proper torque requirements.
3. Repeat tightening the nuts, using the same sequence, gradually 3. Repeat tightening the nuts, using the same sequence, gradually
increasing the torque through a second, third and fourth stage increasing the torque through a second, third and fourth stage
until the final recommended torque is achieved. until the final recommended torque is achieved.
59 59
Figure 59 — Recommended Spring Clip Nut Tightening Sequence Figure 59 — Recommended Spring Clip Nut Tightening Sequence
186 186
MACK AIR SUSPENSIONS MACK AIR SUSPENSIONS

At each C and D inspection interval, check the air springs for cracks, At each C and D inspection interval, check the air springs for cracks,
gouges, distortion, bulges and/or chafing and replace as necessary. If gouges, distortion, bulges and/or chafing and replace as necessary. If
an air spring requires replacement, there is a high likelihood that a an air spring requires replacement, there is a high likelihood that a
problem with another area of the suspension exists. Inspect the problem with another area of the suspension exists. Inspect the
suspension and repair as required. Also at each C and D inspection suspension and repair as required. Also at each C and D inspection
interval, use a solution of soap and water to check the air suspension interval, use a solution of soap and water to check the air suspension
air system for leaks. Check the system for leaks with the vehicle loaded air system for leaks. Check the system for leaks with the vehicle loaded
and the air system at normal operating pressure (governor cut-out). and the air system at normal operating pressure (governor cut-out).
Torque Requirements Torque Requirements
Following any repair that requires the removal and Following any repair that requires the removal and
reinstallation of the spring clips (U-bolts) on AL, AL II, reinstallation of the spring clips (U-bolts) on AL, AL II,
AL-401LH, MAXAIR 40/40A (AL-405), MAXLITE™ AL-401LH, MAXAIR 40/40A (AL-405), MAXLITE™
20–40 and MAXLITE™ 20–40 EZ, the spring clips 20–40 and MAXLITE™ 20–40 EZ, the spring clips
must be retorqued after the first 1 160 km must be retorqued after the first 1 160 km
(1,000 miles) of service, and thereafter at each (1,000 miles) of service, and thereafter at each
specified maintenance interval according to the specified maintenance interval according to the
suspension model as outlined below. Refer to the suspension model as outlined below. Refer to the
MACK Air Suspension and Repair Manual, 14-101, MACK Air Suspension and Repair Manual, 14-101,
MAXAIR 40 (AL-405) Air Suspension and Repair MAXAIR 40 (AL-405) Air Suspension and Repair
Manual, 14-102, or the MAXLITE™ 20–40 EZ Rear Air Manual, 14-102, or the MAXLITE™ 20–40 EZ Rear Air
Suspension, 14-104, for additional information. Suspension, 14-104, for additional information.
187 187
SPRING CLIP RETORQUE — ALL MACK AIR SUSPENSIONS SPRING CLIP RETORQUE — ALL MACK AIR SUSPENSIONS
At the end of the initial break-in period (1 610 km [1,000 miles]), At the end of the initial break-in period (1 610 km [1,000 miles]),
retorque the spring clips (U-bolts) on all chassis equipped with MACK retorque the spring clips (U-bolts) on all chassis equipped with MACK
air suspensions (including MAXAIR™ 40/40A and MAXLITE™ 20–40 air suspensions (including MAXAIR™ 40/40A and MAXLITE™ 20–40
suspensions). Thereafter, spring clips must be retorqued at each A, B, suspensions). Thereafter, spring clips must be retorqued at each A, B,
C and D inspection interval on all chassis equipped with AL, AL II, C and D inspection interval on all chassis equipped with AL, AL II,
AL-401LH and MAXLITE™ 20–40 suspensions. There is no spring clip AL-401LH and MAXLITE™ 20–40 suspensions. There is no spring clip
retorque requirement at any specific service interval (other than at the retorque requirement at any specific service interval (other than at the
end of the initial break-in period) for chassis equipped with the end of the initial break-in period) for chassis equipped with the
MAXAIR™ 40/40A suspension. MAXAIR™ 40/40A suspension.
앫 AL, AL II and AL-401LH — 542–610 N•m (400–450 lb-ft) 앫 AL, AL II and AL-401LH — 542–610 N•m (400–450 lb-ft)
On chassis equipped with AL-401LH and either Eaton On chassis equipped with AL-401LH and either Eaton
or ArvinMeritor rear axles, 3/4-inch diameter U-bolts or ArvinMeritor rear axles, 3/4-inch diameter U-bolts
are used. Torque these U-bolts to 353–434 N•m are used. Torque these U-bolts to 353–434 N•m
(260–320 lb-ft). (260–320 lb-ft).
앫 MAXAIR™ 40/40A — 475–542 N•m (350–400 lb-ft) 앫 MAXAIR™ 40/40A — 475–542 N•m (350–400 lb-ft)
앫 MAXLITE™ 20–40 and 20–40 EZ — 500–650 N•m 앫 MAXLITE™ 20–40 and 20–40 EZ — 500–650 N•m
(369–479 lb-ft) (369–479 lb-ft)
MAIN SUPPORT MEMBER LOCKNUTS MAIN SUPPORT MEMBER LOCKNUTS

At the end of the initial break-in period (1 610 km [1,000 miles]), and At the end of the initial break-in period (1 610 km [1,000 miles]), and
thereafter at each A, B, C and D interval, retorque the main support thereafter at each A, B, C and D interval, retorque the main support
member locknuts on AL, AL II and AL-401LH suspensions as follows: member locknuts on AL, AL II and AL-401LH suspensions as follows:
앫 AL — Main support member to air spring lower mounting 앫 AL — Main support member to air spring lower mounting
bracket — 353–434 N•m (260–320 lb-ft) bracket — 353–434 N•m (260–320 lb-ft)
앫 AL II and AL-401LH — Main support member to cross channel 앫 AL II and AL-401LH — Main support member to cross channel
section — 353–434 N•m (260–320 lb-ft) section — 353–434 N•m (260–320 lb-ft)
앫 MAXLITE™ 20–40 — Main support member to crossbeam — 앫 MAXLITE™ 20–40 — Main support member to crossbeam —
85–125 N•m (62–92 lb-ft) 85–125 N•m (62–92 lb-ft)
188 188
OTHER FASTENERS OTHER FASTENERS

At each D inspection interval, check the torque of the following At each D inspection interval, check the torque of the following
fasteners (refer to the MACK Air Suspension Service and Repair fasteners (refer to the MACK Air Suspension Service and Repair
Manual, 14-101, MAXAIR™ 40 (AL-405) Air Suspension Service and Manual, 14-101, MAXAIR™ 40 (AL-405) Air Suspension Service and
Repair Manual, 14-102, or the MAXLITE™ 20–40 Rear Air Suspension Repair Manual, 14-102, or the MAXLITE™ 20–40 Rear Air Suspension
Service Manual, 14-104, for additional information). Service Manual, 14-104, for additional information).
MACK AL Air Suspensions MACK AL Air Suspensions
Fastener Torque N•m (lb-ft) Fastener Torque N•m (lb-ft)
Air Spring-to-Frame Bracket — 68–95 (50–70) Air Spring-to-Frame Bracket — 68–95 (50–70)
Inboard Inboard
Outboard Outboard
Air Spring-to-Lower Mounting 27–41 (20–30) Air Spring-to-Lower Mounting 27–41 (20–30)
Bracket (Cross Tube) Bracket (Cross Tube)
Longitudinal Torque Rod Bar Pin 203–278 (150–205) Longitudinal Torque Rod Bar Pin 203–278 (150–205)
Transverse Torque Rod, Frame 237–271 (175–200) Transverse Torque Rod, Frame 237–271 (175–200)
Side, Straddle-Type Mount Side, Straddle-Type Mount
Transverse Torque Rod, Axle Side, 237–271 (175–200) Transverse Torque Rod, Axle Side, 237–271 (175–200)
Straddle-Type Mount Straddle-Type Mount
Transverse Torque Rod, Axle-Side, 542–610 (400–450) Transverse Torque Rod, Axle-Side, 542–610 (400–450)
Taper Ball Socket Taper Ball Socket
Frame Bracket Rebound Roller Bolt 68–95 (50–70) Frame Bracket Rebound Roller Bolt 68–95 (50–70)
Shock Absorber, Top and Bottom 68–95 (50–70) Shock Absorber, Top and Bottom 68–95 (50–70)
Nuts Nuts
189 189
MACK AL II and AL-401LH Air Suspensions MACK AL II and AL-401LH Air Suspensions
Outboard Outboard
Air Spring-to-Lower Mounting 27–41 (20–30) Air Spring-to-Lower Mounting 27–41 (20–30)
Bracket (Cross Channel) Bracket (Cross Channel)
Longitudinal Torque Rod Bar Pin 203–278 (150–205) Longitudinal Torque Rod Bar Pin 203–278 (150–205)
Transverse Torque Rod, Frame 237–271 (175–200) Transverse Torque Rod, Frame 237–271 (175–200)
Side, Straddle-Type Mount Side, Straddle-Type Mount
Transverse Torque Rod, Axle Side, 237–271 (175–200) Transverse Torque Rod, Axle Side, 237–271 (175–200)
Straddle-Type Mount Straddle-Type Mount
Frame Bracket Rebound Roller Bolt 68–95 (50–70) Frame Bracket Rebound Roller Bolt 68–95 (50–70)
Shock Absorber, Top and Bottom 122–149 (90–110) Shock Absorber, Top and Bottom 122–149 (90–110)
Nuts (AL II only) Nuts (AL II only)
Shock Absorber, Top Nut (AL-401LH 122–149 (90–110) Shock Absorber, Top Nut (AL-401LH 122–149 (90–110)
only) only)
Shock Absorber, Bottom Stud Nut 68–95 (50–70) Shock Absorber, Bottom Stud Nut 68–95 (50–70)
(AL-401LH only) (AL-401LH only)
MAXLITE™ 20–40 and 20–40 EZ Air Suspensions MAXLITE™ 20–40 and 20–40 EZ Air Suspensions
Air Spring Upper Bracket-to-Frame 167–233 (124-172) Air Spring Upper Bracket-to-Frame 167–233 (124-172)
Air Spring-to-Upper Bracket 50 (37) Air Spring-to-Upper Bracket 50 (37)
Air Spring-to-Crossbeam 50 (37) Air Spring-to-Crossbeam 50 (37)
Transverse Torque Rod-to-Axle 270–370 (199–273) Transverse Torque Rod-to-Axle 270–370 (199–273)
Housing Housing
Transverse Torque Rod-to-Frame 270–370 (199–273) Transverse Torque Rod-to-Frame 270–370 (199–273)
Bracket Bracket
Shock Absorber-to-Bracket Bolts 230–320 (170–236) Shock Absorber-to-Bracket Bolts 230–320 (170–236)
(Upper and Lower) (Upper and Lower)
190 190
Air Suspension Control Switch Air Suspension Control Switch

The air suspension control switch located on the dashboard is used to The air suspension control switch located on the dashboard is used to
exhaust the air from the air suspension air bags when coupling and exhaust the air from the air suspension air bags when coupling and
uncoupling a trailer, or when raising and lowering a dump body. The air uncoupling a trailer, or when raising and lowering a dump body. The air
bags must be reinflated before the vehicle is operated. bags must be reinflated before the vehicle is operated.
On trucks equipped with a dump body, always exhaust On trucks equipped with a dump body, always exhaust
the air from the air bags before raising the body to the air from the air bags before raising the body to
prevent damaging the bags and to improve chassis prevent damaging the bags and to improve chassis
stability while dumping a load. Reinflate the air bags stability while dumping a load. Reinflate the air bags
after lowering the dump body. after lowering the dump body.
Do NOT operate a vehicle with air exhausted from the Do NOT operate a vehicle with air exhausted from the
air suspension air bags, as damage to the chassis air suspension air bags, as damage to the chassis
driveline will result. Always reinflate the air bags after driveline will result. Always reinflate the air bags after
coupling or uncoupling a trailer, or after lowering a coupling or uncoupling a trailer, or after lowering a
dump body. dump body.
Height Control Valve Height Control Valve

At each D inspection interval, check functionality of the height control At each D inspection interval, check functionality of the height control
valve. Refer to the MACK AL and AL II Air Suspension Service and valve. Refer to the MACK AL and AL II Air Suspension Service and
Repair Manual, 14-101, MAXAIR™ 40 (AL-405) Air Suspension Repair Manual, 14-101, MAXAIR™ 40 (AL-405) Air Suspension
Service and Repair Manual, 14-102, or the MAXLITE™ 20–40 Rear Air Service and Repair Manual, 14-102, or the MAXLITE™ 20–40 Rear Air
Suspension Service Manual, 14-104, for additional information. Suspension Service Manual, 14-104, for additional information.
Ride Height — MACK Al, AL II and MAXAIR™ 40/40A Air Ride Height — MACK Al, AL II and MAXAIR™ 40/40A Air
Suspensions Suspensions
Air suspensions function best when the ride height is properly Air suspensions function best when the ride height is properly
adjusted. Check ride height and adjust, if necessary, at each D adjusted. Check ride height and adjust, if necessary, at each D
191 191
Driveline universal joint operating angles are affected Driveline universal joint operating angles are affected
by variations in ride height. Failure to maintain the by variations in ride height. Failure to maintain the
proper ride height setting is likely to lead to driveline proper ride height setting is likely to lead to driveline
vibration, and subsequent drivetrain durability vibration, and subsequent drivetrain durability
problems. problems.
Ride height is measured from the bottom of the frame rail to the bottom Ride height is measured from the bottom of the frame rail to the bottom
of the main support member. For the AL, AL II and AL-401LH, this of the main support member. For the AL, AL II and AL-401LH, this
dimension must be 108 ± 3 mm (4.25 ± 0.125 inch) as shown in the dimension must be 108 ± 3 mm (4.25 ± 0.125 inch) as shown in the
following illustration. following illustration.
60 60

Figure 60 — AL, AL II and AL-401LH Ride Height Dimension Figure 60 — AL, AL II and AL-401LH Ride Height Dimension
This dimension is the most important measurement when adjusting This dimension is the most important measurement when adjusting
ride height. A gauge is available from Hendrickson Truck Suspension ride height. A gauge is available from Hendrickson Truck Suspension
Systems to facilitate checking this dimension. The part number for this Systems to facilitate checking this dimension. The part number for this
gauge is as follows: gauge is as follows:
앫 Hendrickson part No. 45745-050 — AL, Al II, AL-401LH 앫 Hendrickson part No. 45745-050 — AL, Al II, AL-401LH
192 192
Ride height dimensions for the MAXAIR™ 40 suspension depends on Ride height dimensions for the MAXAIR™ 40 suspension depends on
suspension version. To determine the suspension version, look for an suspension version. To determine the suspension version, look for an
“X” located on the spring clip (U-bolt) top cap. “X” located on the spring clip (U-bolt) top cap.
61 61
Figure 61 — MAXAIR™ 40 Spring Clip Top Cap “X” Marking Figure 61 — MAXAIR™ 40 Spring Clip Top Cap “X” Marking
Ride height is measured from the bottom of the frame rail to the bottom Ride height is measured from the bottom of the frame rail to the bottom
of the main support member as shown in the illustration below. of the main support member as shown in the illustration below.
Depending on suspension version, the ride height dimension is as Depending on suspension version, the ride height dimension is as
follows: follows:
앫 If an “X” is present, ride height must be adjusted to 앫 If an “X” is present, ride height must be adjusted to
123.8 mm ± 3.2 mm (4-7/8″ ± 1/8″) (unloaded). 123.8 mm ± 3.2 mm (4-7/8″ ± 1/8″) (unloaded).
앫 If there is no “X” present, ride height must be adjusted to 앫 If there is no “X” present, ride height must be adjusted to
133.4 mm ± 3.2 mm (5-1/4″ ± 1/8″) (unloaded). 133.4 mm ± 3.2 mm (5-1/4″ ± 1/8″) (unloaded).
193 193
62 62

Figure 62 — MAXAIR™ 40 Ride Height Measurement Figure 62 — MAXAIR™ 40 Ride Height Measurement
194 194
It is critical to identify the suspension version to It is critical to identify the suspension version to
determine the ride height setting before making any determine the ride height setting before making any
ride height adjustments. Setting the ride height to the ride height adjustments. Setting the ride height to the
incorrect dimension could result in driveline damage, incorrect dimension could result in driveline damage,
and such damage is not covered under warranty. and such damage is not covered under warranty.
This dimension is the most important measurement when adjusting This dimension is the most important measurement when adjusting
ride height. Gauges are available from Hendrickson Truck Suspension ride height. Gauges are available from Hendrickson Truck Suspension
Systems to facilitate checking this dimension. Part numbers for these Systems to facilitate checking this dimension. Part numbers for these
gauges are as follows: gauges are as follows:
앫 Hendrickson gauge part No. 45745-127 — MAXAIR™ 40/40A 앫 Hendrickson gauge part No. 45745-127 — MAXAIR™ 40/40A
suspension on chassis manufactured prior to 3/1/01 with a ride suspension on chassis manufactured prior to 3/1/01 with a ride
height setting of 123.8 mm ± 3.2 mm (4-7/8″ ± 1/8″) height setting of 123.8 mm ± 3.2 mm (4-7/8″ ± 1/8″)
앫 Hendrickson gauge part No. 45745-164C — MAXAIR™ 40/40A 앫 Hendrickson gauge part No. 45745-164C — MAXAIR™ 40/40A
suspension on chassis manufactured 3/19/01 and later (spring suspension on chassis manufactured 3/19/01 and later (spring
clip caps marked with an “X”) with a ride height setting of clip caps marked with an “X”) with a ride height setting of
123.8 mm ± 3.2 mm (4-7/8″ ± 1/8″) 123.8 mm ± 3.2 mm (4-7/8″ ± 1/8″)
195 195
63 63
Figure 63 — MAXAIR™ 40 Ride Height Gauge 45745-164C and 45745-127 Figure 63 — MAXAIR™ 40 Ride Height Gauge 45745-164C and 45745-127
1. Gauge Part No. 45745-164C for 2. Gauge Part No. 45745-127 for 1. Gauge Part No. 45745-164C for 2. Gauge Part No. 45745-127 for
Chassis Equipped with MaxAir™ Chassis Equipped with MaxAir™ Chassis Equipped with MaxAir™ Chassis Equipped with MaxAir™
40 Suspension Manufactured 40 Suspension Manufactured 40 Suspension Manufactured 40 Suspension Manufactured
3/19/01 and Later (Spring Clip Prior to 3/19/01. 3/19/01 and Later (Spring Clip Prior to 3/19/01.
Caps Marked with “X”). Caps Marked with “X”).
196 196
Ride height must be measured on the axle to which the height- Ride height must be measured on the axle to which the height-
control valve linkage is attached. In most applications, this is usually control valve linkage is attached. In most applications, this is usually
on the left-hand side of the vehicle, at the front-rear axle location. On on the left-hand side of the vehicle, at the front-rear axle location. On
tandem axle assemblies, frame slope may cause the ride height to vary tandem axle assemblies, frame slope may cause the ride height to vary
from the specified dimension on the axle which does not have a height- from the specified dimension on the axle which does not have a height-
control valve. Ride height should be set when the vehicle is unloaded control valve. Ride height should be set when the vehicle is unloaded
and parked on a level surface. Prior to checking or setting ride height, and parked on a level surface. Prior to checking or setting ride height,
drive the vehicle forward and backward a few feet several times, and drive the vehicle forward and backward a few feet several times, and
bring the vehicle to a stop without using the brakes. Chock the wheels bring the vehicle to a stop without using the brakes. Chock the wheels
to prevent the vehicle from moving, and do not set the parking brakes. to prevent the vehicle from moving, and do not set the parking brakes.
With the air system fully pressurized, use the air suspension control With the air system fully pressurized, use the air suspension control
inside the cab to exhaust, then reinflate the air suspension. Wait until inside the cab to exhaust, then reinflate the air suspension. Wait until
airflow to the suspension has stopped, then check ride height. airflow to the suspension has stopped, then check ride height.
On MACK AL, AL II and MAXAIR™ 40/40A air suspensions, changes On MACK AL, AL II and MAXAIR™ 40/40A air suspensions, changes
to ride height are made by adjusting the height-control valve linkage. to ride height are made by adjusting the height-control valve linkage.
The following different height-control valve and linkage configurations The following different height-control valve and linkage configurations
are used on MACK chassis: are used on MACK chassis:
앫 Height-control valve linkage with rubber rod ends 앫 Height-control valve linkage with rubber rod ends
앫 Height-control valve linkage with threaded rod ends 앫 Height-control valve linkage with threaded rod ends
앫 Height-control valve with adjustable arm 앫 Height-control valve with adjustable arm
Ride height adjustment is different for each valve/linkage configuration. Ride height adjustment is different for each valve/linkage configuration.
Adjustment procedures are outlined in the following text. Adjustment procedures are outlined in the following text.
On chassis equipped with height-control valve linkage having rubber On chassis equipped with height-control valve linkage having rubber
rod ends, loosen the hose clamp at the bottom rod end, then slide the rod ends, loosen the hose clamp at the bottom rod end, then slide the
rod end up or down on the linkage rod to achieve the specified ride rod end up or down on the linkage rod to achieve the specified ride
height. Retighten the hose clamp when the adjustment is complete. height. Retighten the hose clamp when the adjustment is complete.
197 197
64 64
Figure 64 — Height-Control Valve Linkage with Rubber Rod Ends Figure 64 — Height-Control Valve Linkage with Rubber Rod Ends
(Except AL-405) (Except AL-405)
198 198
65 65
Figure 65 — Height-Control Valve with Rubber Rod Ends (AL-405) Figure 65 — Height-Control Valve with Rubber Rod Ends (AL-405)
1. Height-Control Valve 4. Extension Arm Rubber Joint 1. Height-Control Valve 4. Extension Arm Rubber Joint
2. Linkage Rod 5. Extension Arm Locknuts 2. Linkage Rod 5. Extension Arm Locknuts
3. Clamp (11–17 N폷m) [100–150 lb-in] 3. Clamp (11–17 N폷m) [100–150 lb-in]
199 199
On chassis equipped with a height-control valve linkage having On chassis equipped with a height-control valve linkage having
threaded rod ends, disconnect the linkage from the bracket on the threaded rod ends, disconnect the linkage from the bracket on the
cross channel. Loosen the jam nut, then turn the rod end to achieve the cross channel. Loosen the jam nut, then turn the rod end to achieve the
specified ride height. Reattach the linkage to the bracket on the cross specified ride height. Reattach the linkage to the bracket on the cross
channel and torque all linkage fasteners (jam nut and attachment channel and torque all linkage fasteners (jam nut and attachment
hardware) to 11–17 N•m (100–150 lb-in). hardware) to 11–17 N•m (100–150 lb-in).
66 66
Figure 66 — Height-Control Valve and Linkage Figure 66 — Height-Control Valve and Linkage
200 200
On chassis equipped with a height-control valve that has an adjustable On chassis equipped with a height-control valve that has an adjustable
arm, the valve has a stud that passes through an elongated hole in the arm, the valve has a stud that passes through an elongated hole in the
arm. The arm is secured with a locknut. To adjust ride height on these arm. The arm is secured with a locknut. To adjust ride height on these
chassis, loosen the control arm locknut and reposition the arm to chassis, loosen the control arm locknut and reposition the arm to
achieve the specified ride height. Retorque the arm locknut to achieve the specified ride height. Retorque the arm locknut to
11–17 N•m (100–150 lb-in). 11–17 N•m (100–150 lb-in).
67 67
Figure 67 — Height-Control Valve with Adjustable Arm Figure 67 — Height-Control Valve with Adjustable Arm
201 201
In addition to the adjustable height-control valve linkages, the height- In addition to the adjustable height-control valve linkages, the height-
control valve on most chassis is adjustable by moving the entire valve control valve on most chassis is adjustable by moving the entire valve
assembly so that ride height can be fine-tuned. On these chassis, one assembly so that ride height can be fine-tuned. On these chassis, one
hole in the valve mounting bracket is elongated to allow for adjustment. hole in the valve mounting bracket is elongated to allow for adjustment.
To fine-tune ride height, loosen the locknuts on the valve mounting To fine-tune ride height, loosen the locknuts on the valve mounting
studs slightly, then rotate the entire valve assembly to achieve the studs slightly, then rotate the entire valve assembly to achieve the
specified ride height. Retorque the valve mounting locknuts to specified ride height. Retorque the valve mounting locknuts to
6–11 N•m (50–100 lb-in). 6–11 N•m (50–100 lb-in).
68 68
Figure 68 — Adjustable Height-Control Valve Figure 68 — Adjustable Height-Control Valve
After ride height adjustments are complete, exhaust and reinflate the After ride height adjustments are complete, exhaust and reinflate the
suspension. Wait until airflow to the suspension has stopped, then suspension. Wait until airflow to the suspension has stopped, then
recheck the ride height. recheck the ride height.
202 202
Ride Height — MaxLite™ 20–40 and 20–40 EZ Air Ride Height — MaxLite™ 20–40 and 20–40 EZ Air
Suspensions Suspensions
Air suspensions function best when the ride height is properly Air suspensions function best when the ride height is properly
adjusted. Check ride height and adjust, if necessary, at each D adjusted. Check ride height and adjust, if necessary, at each D
Driveline universal joint operating angles are affected Driveline universal joint operating angles are affected
by variations in ride height. Failure to maintain the by variations in ride height. Failure to maintain the
proper ride height setting is likely to lead to driveline proper ride height setting is likely to lead to driveline
vibration and subsequent drivetrain durability vibration and subsequent drivetrain durability
problems. problems.
On the MaxLite™ 20–40 and 20–40 EZ air suspensions, ride height is On the MaxLite™ 20–40 and 20–40 EZ air suspensions, ride height is
set to 216 mm (8.5 inches). This dimension is measured from the top of set to 216 mm (8.5 inches). This dimension is measured from the top of
the left-hand axle stop to the top center of the axle housing on the the left-hand axle stop to the top center of the axle housing on the
front-rear axle using ride height gauge part No. TS89604. front-rear axle using ride height gauge part No. TS89604.
203 203
69 69

Figure 69 — Ride Height Measurement Figure 69 — Ride Height Measurement
1. LH Frame Rail 4. Ride Height Dimension 1. LH Frame Rail 4. Ride Height Dimension
2. Adjustment Access Hole 5. Axle Housing 2. Adjustment Access Hole 5. Axle Housing
3. Height Control Valve 6. Ride Height Gauge (TS89604) 3. Height Control Valve 6. Ride Height Gauge (TS89604)
204 204
Ride height must be checked and adjusted when the vehicle is Ride height must be checked and adjusted when the vehicle is
uploaded and parked on a level surface. Prior to checking or adjusting uploaded and parked on a level surface. Prior to checking or adjusting
ride height, perform the following: ride height, perform the following:
앫 Be sure the front steer axle and rear drive axle tires are properly 앫 Be sure the front steer axle and rear drive axle tires are properly
inflated. inflated.
앫 Center the suspension by driving the vehicle back and forth twice 앫 Center the suspension by driving the vehicle back and forth twice
without using the service brakes to bring the vehicle to a stop. without using the service brakes to bring the vehicle to a stop.
앫 Do not apply the parking brakes. 앫 Do not apply the parking brakes.
앫 Place blocks under the front wheels to prevent the vehicle from 앫 Place blocks under the front wheels to prevent the vehicle from
moving. moving.
앫 Make sure the front wheels are pointing straight ahead. 앫 Make sure the front wheels are pointing straight ahead.
앫 Make sure the transmission is in neutral. 앫 Make sure the transmission is in neutral.
Measure ride height as follows: Measure ride height as follows:

1. Completely exhaust the air pressure from the suspension. 1. Completely exhaust the air pressure from the suspension.
Stay clear of the chassis when air pressure from Stay clear of the chassis when air pressure from
the suspension is being exhausted. The chassis the suspension is being exhausted. The chassis
can drop quickly, which can cause serious injury can drop quickly, which can cause serious injury
or death to anyone underneath the vehicle. or death to anyone underneath the vehicle.
2. Start the engine and use the suspension switch in the cab to 2. Start the engine and use the suspension switch in the cab to
inflate the suspension. inflate the suspension.
3. Shut the engine off, then use the ride height gauge (part No. 3. Shut the engine off, then use the ride height gauge (part No.
TS89604) to measure ride height. Ride height should be 216 mm TS89604) to measure ride height. Ride height should be 216 mm
(8.5 inches) as indicated by the gauge. (8.5 inches) as indicated by the gauge.
205 205
If ride height is not within specifications, adjust as follows: If ride height is not within specifications, adjust as follows:
Ride height must be adjusted with the vehicle Ride height must be adjusted with the vehicle
unloaded, parked on a level surface, transmission in unloaded, parked on a level surface, transmission in
neutral and the front wheels blocked to prevent the neutral and the front wheels blocked to prevent the
vehicle from moving. vehicle from moving.
1. Loosen the height control valve bracket mounting bolt so that the 1. Loosen the height control valve bracket mounting bolt so that the
bracket is free to pivot about the bolt. bracket is free to pivot about the bolt.
2. Insert the adjustment socket (tool No. J 44544) through the 2. Insert the adjustment socket (tool No. J 44544) through the
access hole located in the frame. access hole located in the frame.
70 70

Figure 70 — Adjusting Ride Height Figure 70 — Adjusting Ride Height
1. Access Hole (LH Frame Rail) 2. Adjustment Socket J 44544 1. Access Hole (LH Frame Rail) 2. Adjustment Socket J 44544
206 206
3. Adjust ride height by rotating the valve and bracket as follows: 3. Adjust ride height by rotating the valve and bracket as follows:
앫 Rotate clockwise to raise ride height. 앫 Rotate clockwise to raise ride height.
앫 Rotate counterclockwise to lower ride height. 앫 Rotate counterclockwise to lower ride height.
4. Once proper ride height is obtained, tighten the height control 4. Once proper ride height is obtained, tighten the height control
valve mounting bracket bolt to 50 N폷m (37 lb-ft). valve mounting bracket bolt to 50 N폷m (37 lb-ft).
5. Remove the adjustment socket from the frame, and then exhaust 5. Remove the adjustment socket from the frame, and then exhaust
and reinflate the suspension. Wait until airflow to the suspension and reinflate the suspension. Wait until airflow to the suspension
has stopped, then recheck ride height. Readjust as necessary. has stopped, then recheck ride height. Readjust as necessary.
207 207
AXLE ALIGNMENT AXLE ALIGNMENT
For vehicles equipped with the MACK RSA (Road For vehicles equipped with the MACK RSA (Road
Stability Advantage) program (Bendix ABS-6 Stability Advantage) program (Bendix ABS-6
Advanced with ESP [Electronic Stability Program]), Advanced with ESP [Electronic Stability Program]),
any adjustments to vehicle alignment requires any adjustments to vehicle alignment requires
recalibration of the steering angle sensor. For recalibration of the steering angle sensor. For
information, refer to the Bendix Service Data Sheet information, refer to the Bendix Service Data Sheet
(SD-13-4869). This data sheet can be obtained by (SD-13-4869). This data sheet can be obtained by
visiting the Bendix website at www.bendix.com. visiting the Bendix website at www.bendix.com.
Jack up the front end and shake the wheels Jack up the front end and shake the wheels
horizontally. Wheel bearing end play must be within horizontally. Wheel bearing end play must be within
0.025 to 0.13 mm (0.001 to 0.005 inch). Check all 0.025 to 0.13 mm (0.001 to 0.005 inch). Check all
steering linkage components for excessive looseness. steering linkage components for excessive looseness.
These steps must be taken so as not to introduce These steps must be taken so as not to introduce
errors into geometry readings when checking toe-in, errors into geometry readings when checking toe-in,
camber and caster. Also check for proper tire camber and caster. Also check for proper tire
pressure. pressure.
Check axle alignment at first A inspection interval, thereafter at Check axle alignment at first A inspection interval, thereafter at
each C and D inspection for front axles and each D inspection for each C and D inspection for front axles and each D inspection for
rear axles. rear axles.
208 208
TOE-IN SPECIFICATIONS* TOE-IN SPECIFICATIONS*
MACK non-driving front axles: 1/16″ ± 1/32″ (.06″ ± .03″) or MACK non-driving front axles: 1/16″ ± 1/32″ (.06″ ± .03″) or
FAW 12, 14.3, FA(W) 18, 20, FA23 0°4′ ± .0°2’ (0°2’ to 0°6’) or FAW 12, 14.3, FA(W) 18, 20, FA23 0°4′ ± .0°2’ (0°2’ to 0°6’) or
and FXL 12, 14.6, 18, 20, 23 .07° ± .035° (.035° to .11°) or and FXL 12, 14.6, 18, 20, 23 .07° ± .035° (.035° to .11°) or
1.5 mm/m ± .75 mm/m 1.5 mm/m ± .75 mm/m
ArvinMeritor™, Eaton/Dana 1/16″ ± 1/32″ (.06″ ± .03″) or ArvinMeritor™, Eaton/Dana 1/16″ ± 1/32″ (.06″ ± .03″) or
non-driving front axles 0°4′ ± 0°2’ (0°2′ to 0°6′) or non-driving front axles 0°4′ ± 0°2’ (0°2′ to 0°6′) or
.07° ± .035° (.035° to .11°) or .07° ± .035° (.035° to .11°) or
1.5 mm/m ± .75 mm/m 1.5 mm/m ± .75 mm/m
ArvinMeritor™ and 1/16″ ± 1/16″ (.06″ ± .06″) or ArvinMeritor™ and 1/16″ ± 1/16″ (.06″ ± .06″) or
Marmon-Herrington front driving 0°4′ ± 0°4′ (0° to 0°8′) or Marmon-Herrington front driving 0°4′ ± 0°4′ (0° to 0°8′) or
axles .07° ± .07° (0° to .14°) or axles .07° ± .07° (0° to .14°) or
1.5 mm/m ± 1.5 mm/m 1.5 mm/m ± 1.5 mm/m
AIRTEK 12.5K, 13.2K and 14.6K 1/16″ +0″/ -1/16″ (.06″ +0″/ -.06″) or AIRTEK 12.5K, 13.2K and 14.6K 1/16″ +0″/ -1/16″ (.06″ +0″/ -.06″) or
non-driving front axle with air 0°4’ +0°/ -0°4’ (0°4’ to 0°0’) or non-driving front axle with air 0°4’ +0°/ -0°4’ (0°4’ to 0°0’) or
suspension .07° +0°/ -.07° or suspension .07° +0°/ -.07° or
1.5 mm/m +0 mm/m -1.5 mm/m 1.5 mm/m +0 mm/m -1.5 mm/m
* Set toe toward zero side of specification on vehicles equipped with steel * Set toe toward zero side of specification on vehicles equipped with steel
belted radial tires or vehicles with lightly loaded front axles. belted radial tires or vehicles with lightly loaded front axles.
TOE-OUT SPECIFICATIONS* TOE-OUT SPECIFICATIONS*
Note: Toe-out * 1/16″ ± 1/16″ (.06″ ± .06″) or Note: Toe-out * 1/16″ ± 1/16″ (.06″ ± .06″) or
FABCO Front Driving Axles 0°4′ ± 0°4′ (0° to 0°8′) or FABCO Front Driving Axles 0°4′ ± 0°4′ (0° to 0°8′) or
(SDA1800, 2100, 2300) .07° ± .07° (0° to .14°) or (SDA1800, 2100, 2300) .07° ± .07° (0° to .14°) or
1.5 mm/m ± 1.5 mm/m 1.5 mm/m ± 1.5 mm/m
* HUNTER and JOSAM alignment equipment measurements indicating toe-out * HUNTER and JOSAM alignment equipment measurements indicating toe-out
will be expressed as a negative number, i.e., −.07° for HUNTER, −1.5 mm/m will be expressed as a negative number, i.e., −.07° for HUNTER, −1.5 mm/m
for JOSAM. for JOSAM.
71 71
Figure 71 — Toe Measurements Figure 71 — Toe Measurements
209 209
CAMBER SPECIFICATIONS CAMBER SPECIFICATIONS
MACK non-driving front axles: MACK non-driving front axles:

FAW 12, 14.3 0° ± 7/16° (0° ± .43°) FAW 12, 14.3 0° ± 7/16° (0° ± .43°)
FA(W) 18, 20 1/4° ± 7/16° (.25° ± .43°) FA(W) 18, 20 1/4° ± 7/16° (.25° ± .43°)
FA23 3/4° ± 7/16° (.75° ± .43°) FA23 3/4° ± 7/16° (.75° ± .43°)
FXL 12, 14.6, 18, 20, 23 1/4° ± 7/16° (.25° ± .43°) FXL 12, 14.6, 18, 20, 23 1/4° ± 7/16° (.25° ± .43°)
AIRTEK 12.5, 13.2 and 14.6 Front AIRTEK 12.5, 13.2 and 14.6 Front
Axles: Axles:
Left side camber 0° ± 1/2° (0° ± .5°) Left side camber 0° ± 1/2° (0° ± .5°)
Right side camber 0° ± 1/2° (0° ± .5°) Right side camber 0° ± 1/2° (0° ± .5°)
Cross Camber 0° to maximum 1° Cross Camber 0° to maximum 1°
Dana non-driving front axles: Dana non-driving front axles:
E-1202I E-1202I
Left side camber 1/8° ± 7/16° (.13° ± .43°) Left side camber 1/8° ± 7/16° (.13° ± .43°)
Right side camber –1/8° ± 7/16° (–.13° ± .43°) Right side camber –1/8° ± 7/16° (–.13° ± .43°)
ArvinMeritor™ non-driving front –0°41′ to 0°11′ ArvinMeritor™ non-driving front –0°41′ to 0°11′
axles axles
–.69° to .19° –.69° to .19°
–11/16° to 3/16° –11/16° to 3/16°
Driving front axles: Driving front axles:
ArvinMeritor™ 0° to 1/2° (0° to .5°) ArvinMeritor™ 0° to 1/2° (0° to .5°)
FABCO (SDA1800, 2100, 2300) 1/4° to 3/4° (.25° to .75°) FABCO (SDA1800, 2100, 2300) 1/4° to 3/4° (.25° to .75°)
Marmon-Herrington (MT23) 13/32° to 39/64° (.4° to .6°) Marmon-Herrington (MT23) 13/32° to 39/64° (.4° to .6°)
All measurements must be taken with the vehicle in the unloaded condition. All measurements must be taken with the vehicle in the unloaded condition.
Specifications for vehicles built prior to 1993 may be different. See previously Specifications for vehicles built prior to 1993 may be different. See previously
published information, or alignment equipment manufacturer’s charts for published information, or alignment equipment manufacturer’s charts for
specifications on older vehicles. specifications on older vehicles.
72 72
Figure 72 — Camber Angles Figure 72 — Camber Angles
210 210
CASTER SPECIFICATIONS CASTER SPECIFICATIONS
Single non-driving front axle: Single non-driving front axle:
MRU, LEU 4° to 6° MRU, LEU 4° to 6°
CXU, CHU, GU7, GU8 3° to 5° CXU, CHU, GU7, GU8 3° to 5°
Single front driving axle: Single front driving axle:
All (except Marmon-Herrington (MT23)) 3°30′ to 5°30′ (3.5° to 5.5°) All (except Marmon-Herrington (MT23)) 3°30′ to 5°30′ (3.5° to 5.5°)
Marmon-Herrington (MT23) 2°30′ to 4°30′ (2.5° to 4.5°) Marmon-Herrington (MT23) 2°30′ to 4°30′ (2.5° to 4.5°)
Two front axles: Two front axles:
Front drive axle 3°30′ to 5°30′ (3.5° to 5.5°) Front drive axle 3°30′ to 5°30′ (3.5° to 5.5°)
Front non-driving front axle 4° to 6° Front non-driving front axle 4° to 6°
Rear non-driving front axle 4°30′ to 6°30′ (4.5° to 6.5°) Rear non-driving front axle 4°30′ to 6°30′ (4.5° to 6.5°)
AIRTEK 12, 13.2, 14.6 AIRTEK 12, 13.2, 14.6
Left Side 3.75° +1°/−0.5° Left Side 3.75° +1°/−0.5°
Right Side 3.75° +1°/−0.5° Right Side 3.75° +1°/−0.5°
Cross Caster 0° to maximum 1.5° Cross Caster 0° to maximum 1.5°
All measurements must be taken with the vehicle in the unloaded condition, All measurements must be taken with the vehicle in the unloaded condition,
and the steering axle and drive axle(s) on a level surface. and the steering axle and drive axle(s) on a level surface.
RH and LH caster readings must not vary more than 0°30′ (.5°). RH and LH caster readings must not vary more than 0°30′ (.5°).
73 73
Figure 73 — Caster Angles Figure 73 — Caster Angles
211 211
Rear Drive Axle Alignment Specifications Rear Drive Axle Alignment Specifications
THRUST THRUST
Adjustable Suspensions 0″ ± 1/8″ (0″ ± .125″) 0° ± .08° Adjustable Suspensions 0″ ± 1/8″ (0″ ± .125″) 0° ± .08°
0 mm/m ± 1.4 mm/m 0 mm/m ± 1.4 mm/m
Non-adjustable 0″ ± 1/4″ (0″ ± .25″) 0° ± .16° Non-adjustable 0″ ± 1/4″ (0″ ± .25″) 0° ± .16°
0 mm/m ± 2.8 mm/m 0 mm/m ± 2.8 mm/m
Specifications are for Thrust Angles on Rear Drive Axles Specifications are for Thrust Angles on Rear Drive Axles
SCRUB (Parallelism) SCRUB (Parallelism)
Adjustable Suspensions 0° ± 1/8″ (0″ ± .125″) 0° ± .08° Adjustable Suspensions 0° ± 1/8″ (0″ ± .125″) 0° ± .08°
0 mm/m ± 1.4 mm/m 0 mm/m ± 1.4 mm/m
Non-adjustable Suspensions 0″ ± 1/4″ (0″ ± .25″) 0° ± .16° Non-adjustable Suspensions 0″ ± 1/4″ (0″ ± .25″) 0° ± .16°
0 mm/m ± 2.8 mm/m 0 mm/m ± 2.8 mm/m
Specifications are for Scrub (Parallelism) on Rear Drive Axles Specifications are for Scrub (Parallelism) on Rear Drive Axles
212 212
AUXILIARY AXLES AUXILIARY AXLES

At each A, B, C and D inspection interval, check pivot bolt torque on At each A, B, C and D inspection interval, check pivot bolt torque on
both steerable and non-steerable liftable axles. Torque specification is both steerable and non-steerable liftable axles. Torque specification is
610 N•m (450 lb-ft). 610 N•m (450 lb-ft).
74 74

Figure 74 — Liftable Axle Pivot Bolts Figure 74 — Liftable Axle Pivot Bolts
1. Steerable Axle 3. Pivot Bolts 1. Steerable Axle 3. Pivot Bolts

2. Non-steerable Axle 2. Non-steerable Axle
On steerable auxiliary axles, check the king pins and bushings for wear On steerable auxiliary axles, check the king pins and bushings for wear
at each C and D inspection interval. Procedures are as follows: at each C and D inspection interval. Procedures are as follows:
1. Fully raise the axle and support the axle beam at the outer ends 1. Fully raise the axle and support the axle beam at the outer ends
to eliminate any rocking motion. to eliminate any rocking motion.
2. Have an assistant fully apply the service brakes. This will 2. Have an assistant fully apply the service brakes. This will
eliminate any motion of the wheel assembly relative to the eliminate any motion of the wheel assembly relative to the
steering knuckle. steering knuckle.
3. Position the tip of a dial indicator on the sidewall of the tire at a 3. Position the tip of a dial indicator on the sidewall of the tire at a
location 444.5 mm (17-1/2″) below the centerline of the hub. location 444.5 mm (17-1/2″) below the centerline of the hub.
4. Zero the dial indicator, and then rock the tire in and out at the top 4. Zero the dial indicator, and then rock the tire in and out at the top
while noting the reading on the dial indicator. while noting the reading on the dial indicator.
5. Readings greater than 3.175 mm (0.125 in.) indicate king pin 5. Readings greater than 3.175 mm (0.125 in.) indicate king pin
bushing wear. Replace king pins and bushings as required. bushing wear. Replace king pins and bushings as required.
213 213
At each D inspection interval, check the torque of the following At each D inspection interval, check the torque of the following
fasteners: fasteners:
Torque Torque
mm (Inch) Specification mm (Inch) Specification
Fastener Description Fastener Size N•m (lb-ft) Fastener Description Fastener Size N•m (lb-ft)
Suspension Air Bag (bottom) 8.5 (3/8) 34 (25) Suspension Air Bag (bottom) 8.5 (3/8) 34 (25)
Suspension Air Bag (top) 12.7 (1/2) 34 (25) Suspension Air Bag (top) 12.7 (1/2) 34 (25)
Suspension Air Bag (top) 19 (3/4) 61 (45) Suspension Air Bag (top) 19 (3/4) 61 (45)
Tie Rod Clamp Bolt 12.7 (1/2) 68 (50) Tie Rod Clamp Bolt 12.7 (1/2) 68 (50)
214 214
WHEEL TORQUE PROCEDURES WHEEL TORQUE PROCEDURES

Spoke Wheels Spoke Wheels
Tighten the wheel nuts in the sequence shown below. When replacing Tighten the wheel nuts in the sequence shown below. When replacing
tire and rim assemblies, tighten lightly the first time and hold runout to tire and rim assemblies, tighten lightly the first time and hold runout to
under 3.2 mm (1/8 inch). Tighten nuts a quarter turn at a time, in under 3.2 mm (1/8 inch). Tighten nuts a quarter turn at a time, in
sequence, to the torques listed below and recheck. sequence, to the torques listed below and recheck.
It is recommended that final nut tightening be done with a torque It is recommended that final nut tightening be done with a torque
wrench. If an air impact wrench is used, periodic checks should wrench. If an air impact wrench is used, periodic checks should
be made with a torque wrench to ensure the accuracy and be made with a torque wrench to ensure the accuracy and
condition of the air wrench. The torque of the air impact wrench condition of the air wrench. The torque of the air impact wrench
also depends upon the air line pressure from which it is operated. also depends upon the air line pressure from which it is operated.
75 75
Figure 75 — Spoke Wheel Nut Tightening Sequence Figure 75 — Spoke Wheel Nut Tightening Sequence
215 215
SPOKE WHEEL TORQUE SPECIFICATIONS SPOKE WHEEL TORQUE SPECIFICATIONS
Description Stud Nut Size Torque N•m (Lb-ft)* Description Stud Nut Size Torque N•m (Lb-ft)*
Front Wheel Clamp Stud 5/8″-11 UNC 165–183 (122–135) Front Wheel Clamp Stud 5/8″-11 UNC 165–183 (122–135)
Nuts Nuts
Nuts (except FA18 and FA20 Nuts (except FA18 and FA20
Series Axles) Series Axles)
Nuts (FA[W]18 and FA[W]20 Nuts (FA[W]18 and FA[W]20
Series Axles) Series Axles)
Rear Wheel Clamp Stud 3/4″-10 UNC 237–305 (175–225) Rear Wheel Clamp Stud 3/4″-10 UNC 237–305 (175–225)
Nuts Nuts
* Threads must be dry. * Threads must be dry.
See following note. See following note.
Before installation of the wheel assemblies, thoroughly Before installation of the wheel assemblies, thoroughly
clean the brake drum, hub and rim assembly surfaces clean the brake drum, hub and rim assembly surfaces
(particularly in the case of hub piloted wheels). After (particularly in the case of hub piloted wheels). After
any procedure that requires the removal and any procedure that requires the removal and
reinstallation of the wheel assemblies, retorque the reinstallation of the wheel assemblies, retorque the
wheel nuts during the first 80–161 km (50–100 miles) wheel nuts during the first 80–161 km (50–100 miles)
of use. of use.
216 216
Disc Wheels (Stud Piloted Ball Seat) Disc Wheels (Stud Piloted Ball Seat)
Single Disc Wheels (Stud Piloted Ball Seat) — Tighten the wheel Single Disc Wheels (Stud Piloted Ball Seat) — Tighten the wheel
nuts in the sequence shown below to the specified torque value given nuts in the sequence shown below to the specified torque value given
in table on page 222. in table on page 222.
76 76
Figure 76 — Disc Wheels with Stud Piloted Ball Seat Tightening Figure 76 — Disc Wheels with Stud Piloted Ball Seat Tightening
Sequence Sequence
Dual Disc Wheels (Stud Piloted Ball Seat) — Loosen outer wheel Dual Disc Wheels (Stud Piloted Ball Seat) — Loosen outer wheel
nuts first, then tighten the inner nuts in sequence shown (Figure 76) to nuts first, then tighten the inner nuts in sequence shown (Figure 76) to
the specified torque value given in table on page 222. After inner nuts the specified torque value given in table on page 222. After inner nuts
are tightened, tighten outer wheel nuts, in sequence, to the specified are tightened, tighten outer wheel nuts, in sequence, to the specified
torque value. torque value.
When installing wheels, tighten wheel nuts lightly first, then tighten a When installing wheels, tighten wheel nuts lightly first, then tighten a
quarter turn at a time, in sequence, to the specified torque and quarter turn at a time, in sequence, to the specified torque and
recheck. When installing dual wheels, install the inner wheel first. Use recheck. When installing dual wheels, install the inner wheel first. Use
the above procedure to tighten the inner wheel nuts. After the inner the above procedure to tighten the inner wheel nuts. After the inner
wheels have been installed, use the same procedure to install the outer wheels have been installed, use the same procedure to install the outer
wheels. wheels.
217 217
Disc Wheels (Hub Piloted) Disc Wheels (Hub Piloted)

Single and Dual Disc Wheels — Mounting faces of the hub, flange Single and Dual Disc Wheels — Mounting faces of the hub, flange
mounting surfaces of the wheels and mounting surfaces of the flange mounting surfaces of the wheels and mounting surfaces of the flange
nuts should be clean and free of any foreign material or excess paint. nuts should be clean and free of any foreign material or excess paint.
The hub pilot pads should also be free of paint. To prevent corrosion, The hub pilot pads should also be free of paint. To prevent corrosion,
anti-sieze compound may be applied to the hub pilot pads. Primer and anti-sieze compound may be applied to the hub pilot pads. Primer and
paint thickness on critical mounting surfaces of each wheel should not paint thickness on critical mounting surfaces of each wheel should not
total more than 0.0762 mm (0.003-inch) maximum. The hub and drum total more than 0.0762 mm (0.003-inch) maximum. The hub and drum
critical mounting surfaces should not be painted. critical mounting surfaces should not be painted.
77 77
Figure 77 — Flanged Nut Installation Figure 77 — Flanged Nut Installation
When installing flanged nuts, apply two drops of oil on the leading When installing flanged nuts, apply two drops of oil on the leading
threads of each stud, and if the flange nuts have been used before, threads of each stud, and if the flange nuts have been used before,
apply two drops of oil to the junction of the nut and flange of each apply two drops of oil to the junction of the nut and flange of each
flange nut. DO NOT get oil between the flange and the wheel. flange nut. DO NOT get oil between the flange and the wheel.
218 218
To install hub piloted wheels: To install hub piloted wheels:

1. Locate one of the hub pilot pads at the 12 o’clock position. 1. Locate one of the hub pilot pads at the 12 o’clock position.
Before mounting the wheels, be sure the drum is Before mounting the wheels, be sure the drum is
properly positioned on the raised step of the pilot pad. properly positioned on the raised step of the pilot pad.
2. With the wheel(s) square to the hub, mount the wheel(s) as far 2. With the wheel(s) square to the hub, mount the wheel(s) as far
back on the pilot pad as possible. Be careful not to scrape the back on the pilot pad as possible. Be careful not to scrape the
stud threads when installing the wheel(s). Install the flange nuts stud threads when installing the wheel(s). Install the flange nuts
and hand-tighten. and hand-tighten.
3. Starting at the top stud position, partially torque the nuts in the 3. Starting at the top stud position, partially torque the nuts in the
sequence as shown in the illustration Figure 76. sequence as shown in the illustration Figure 76.
4. Using the same sequence, torque the flange nuts to the final 4. Using the same sequence, torque the flange nuts to the final
torque as given in table on page 222. torque as given in table on page 222.
DO NOT use cone locknuts on stud located wheels, or DO NOT use cone locknuts on stud located wheels, or
ball-seat type nuts on hub piloted wheels. Sufficient ball-seat type nuts on hub piloted wheels. Sufficient
contact surface between the nut and wheel will not be contact surface between the nut and wheel will not be
obtained, which may result in wheel loss. obtained, which may result in wheel loss.
219 219
Retorquing Hub Piloted Wheels Retorquing Hub Piloted Wheels

Hub piloted wheels must be retorqued during the first 80–161 km Hub piloted wheels must be retorqued during the first 80–161 km
(50–100 miles) following any procedure that requires the removal and (50–100 miles) following any procedure that requires the removal and
reinstallation of the wheel assemblies. Always retorque the flange nuts reinstallation of the wheel assemblies. Always retorque the flange nuts
when the components are at ambient temperature. when the components are at ambient temperature.
78 78
Figure 78 — Disc Wheel Assembly (Stud Piloted Ball Seat) Figure 78 — Disc Wheel Assembly (Stud Piloted Ball Seat)
220 220
79 79
Figure 79 — Hub Piloted Wheels Figure 79 — Hub Piloted Wheels
221 221
WHEEL NUT TORQUE SPECIFICATIONS WHEEL NUT TORQUE SPECIFICATIONS
Stud Nut Size and Stud Nut Size and

Description Type Torque N•m (Lb-ft)* Description Type Torque N•m (Lb-ft)*
Cap Nuts — Single 3/4″-16 UNF shoulder 610–678 (450–500) Cap Nuts — Single 3/4″-16 UNF shoulder 610–678 (450–500)
(front) or inner and (front) or inner and
outer (rear) with 1-1/8″-16 UNF 610–678 (450–500) outer (rear) with 1-1/8″-16 UNF 610–678 (450–500)
shoulder or head-type shoulder shoulder or head-type shoulder
studs (3/4″ backnut) studs (3/4″ backnut)
1-1/8″-16 UNF 881–1017 (650–750) 1-1/8″-16 UNF 881–1017 (650–750)
shoulder shoulder
(7/8″ or 1″ backnut) (7/8″ or 1″ backnut)
1-1/8″-16 UNF head 610–678 (450–500) 1-1/8″-16 UNF head 610–678 (450–500)
15/16″-12 UNF 1017–1220 (750–900) 15/16″-12 UNF 1017–1220 (750–900)
shoulder or head shoulder or head
1-5/16″-12 UNF 1017–1220 (750–900) 1-5/16″-12 UNF 1017–1220 (750–900)
shoulder or head shoulder or head
Backnut (inner end of 3/4″-16 UNF 237–271 (175–200) Backnut (inner end of 3/4″-16 UNF 237–271 (175–200)
wheel stud: shoulder- 7/8″-14 UNF 237–339 (175–250) wheel stud: shoulder- 7/8″-14 UNF 237–339 (175–250)
type studs with threads 1″-14 UNF 237–407 (175–300) type studs with threads 1″-14 UNF 237–407 (175–300)
on both ends) on both ends)
Flange nuts for hub M22 x 1.5 (metric 610–678 (450–500)** Flange nuts for hub M22 x 1.5 (metric 610–678 (450–500)**
piloted wheels threads) piloted wheels threads)
* Threads must be dry. * Threads must be dry.

** If the wheels have been removed, apply a small amount of oil to the lead ** If the wheels have been removed, apply a small amount of oil to the lead
threads of the stud and between the nut body and flange of the cone locknut threads of the stud and between the nut body and flange of the cone locknut
when reinstalling. Avoid getting oil on the face of the nut, wheels or tires. when reinstalling. Avoid getting oil on the face of the nut, wheels or tires.
Chain Clearance Spacers Chain Clearance Spacers

Some chassis may be equipped with rear axle chain clearance spacers Some chassis may be equipped with rear axle chain clearance spacers
to provide additional clearance between the dual rear wheels and rear to provide additional clearance between the dual rear wheels and rear
suspension components if tire chains are to be used. The spacer suspension components if tire chains are to be used. The spacer
shown in the illustration below is used on chassis that are equipped shown in the illustration below is used on chassis that are equipped
with disc wheels. This type of spacer bolts to the hub assembly, and, with disc wheels. This type of spacer bolts to the hub assembly, and,
depending upon rear wheel size and configuration, one or two spacers depending upon rear wheel size and configuration, one or two spacers
may be used. On chassis equipped with spoke wheels, different may be used. On chassis equipped with spoke wheels, different
configuration chain clearance spacers are used. These spacers slide configuration chain clearance spacers are used. These spacers slide
over, but are not bolted to, the hub assembly. over, but are not bolted to, the hub assembly.
222 222
On those chassis having chain spacers bolted to the hub assembly, On those chassis having chain spacers bolted to the hub assembly,
mounting nut torque should be checked at each A, B, C and D mounting nut torque should be checked at each A, B, C and D
inspection interval. Wheel removal is necessary when mounting nut inspection interval. Wheel removal is necessary when mounting nut
torque is checked. Also, if the chassis uses two spacers, it is necessary torque is checked. Also, if the chassis uses two spacers, it is necessary
to remove the outer spacer to check the inner spacer nut torque. to remove the outer spacer to check the inner spacer nut torque.
Using the tightening sequence illustrated below, torque the chain Using the tightening sequence illustrated below, torque the chain
spacer mounting nuts to a value of 610–678 N•m (450–500 lb-ft). spacer mounting nuts to a value of 610–678 N•m (450–500 lb-ft).
80 80
Figure 80 — Wheel Nut Tightening Sequence with Chain Clearance Figure 80 — Wheel Nut Tightening Sequence with Chain Clearance
Spacers Spacers
After any procedure that requires the removal and After any procedure that requires the removal and
reinstallation of the wheel assemblies, retorque the reinstallation of the wheel assemblies, retorque the
wheel nuts during the first 80–161 km (50–100 miles) wheel nuts during the first 80–161 km (50–100 miles)
of use. of use.
223 223
TIRE INFORMATION TIRE INFORMATION

Tire Inspection Tire Inspection
Inspect tires daily, and look for bulges, cuts, penetrations, uneven wear Inspect tires daily, and look for bulges, cuts, penetrations, uneven wear
and/or oil contamination. If any damage is found, the tire must be and/or oil contamination. If any damage is found, the tire must be
thoroughly inspected by a qualified tire inspector and repaired or thoroughly inspected by a qualified tire inspector and repaired or
replaced immediately, at his discretion. replaced immediately, at his discretion.
If uneven tire wear is found, a thorough inspection of the chassis, If uneven tire wear is found, a thorough inspection of the chassis,
inspecting those items that influence tire wear, should be performed. inspecting those items that influence tire wear, should be performed.
Chassis inspection and alignment must be performed by a qualified Chassis inspection and alignment must be performed by a qualified
technician. technician.
Factors That Influence Tire Wear Factors That Influence Tire Wear
The following factors will influence tire wear, affecting both wear rate The following factors will influence tire wear, affecting both wear rate
and uneven tire wear: and uneven tire wear:
앫 Tire Pressure and Loading 앫 Tire Pressure and Loading
앫 King Pin Play 앫 King Pin Play
앫 Toe Adjustment 앫 Toe Adjustment
앫 Axle Alignment 앫 Axle Alignment
앫 Tire Selection and Matching 앫 Tire Selection and Matching
앫 Turning Angle 앫 Turning Angle
앫 Wheel Balance 앫 Wheel Balance
앫 Shock Absorbers 앫 Shock Absorbers
앫 Wheel Runout, Radial and Lateral 앫 Wheel Runout, Radial and Lateral
앫 Vocation (How the Chassis Is Used) 앫 Vocation (How the Chassis Is Used)
앫 Tire Condition/Damage 앫 Tire Condition/Damage
앫 Spring Pin Play 앫 Spring Pin Play
앫 Oil Contamination 앫 Oil Contamination
앫 Torque Rod Play 앫 Torque Rod Play
앫 Tire Mounting 앫 Tire Mounting
224 224
앫 Fifth Wheel Setting 앫 Fifth Wheel Setting

앫 Tie Rod End Play 앫 Tie Rod End Play
앫 Wheel Bearing Play 앫 Wheel Bearing Play
앫 Lack of Lubrication on Fifth Wheel Top Plate 앫 Lack of Lubrication on Fifth Wheel Top Plate
Oil Contamination of Tires Oil Contamination of Tires

Oil contamination will soften rubber and eventually destroy the tire. Oil contamination will soften rubber and eventually destroy the tire.
Ensure that oil leakage does not occur by inspecting the following Ensure that oil leakage does not occur by inspecting the following
areas regularly: areas regularly:
앫 Engine oil seals 앫 Engine oil seals
앫 Transmission oil seals 앫 Transmission oil seals
앫 Axle hub seals 앫 Axle hub seals
앫 Drive axle seals 앫 Drive axle seals
앫 Oil filters and oil lines 앫 Oil filters and oil lines
Tire Selection Tire Selection

Select the proper tire for the vehicle vocation and axle position. Tire Select the proper tire for the vehicle vocation and axle position. Tire
selection should be matched to the manufacturer’s application selection should be matched to the manufacturer’s application
guidelines. Consult a qualified tire specialist for proper tire selection. guidelines. Consult a qualified tire specialist for proper tire selection.
The overall ratio of an axle is affected by the number of revolutions the The overall ratio of an axle is affected by the number of revolutions the
tires make in a mile, and will change if tire size, make, ply type and tires make in a mile, and will change if tire size, make, ply type and
tread design are changed. Particularly on all-wheel-drive vehicles tread design are changed. Particularly on all-wheel-drive vehicles
using the MACK TC(S) 15/25 transfer case, overall ratio match using the MACK TC(S) 15/25 transfer case, overall ratio match
between the front and rear axles must be maintained or damage to the between the front and rear axles must be maintained or damage to the
front drive axle, driveline or transfer case may result. Unless front drive axle, driveline or transfer case may result. Unless
replacement tires are identical to the originals, consult your MACK replacement tires are identical to the originals, consult your MACK
distributor or service facility to select replacements that will maintain distributor or service facility to select replacements that will maintain
ratio match within acceptable limits. ratio match within acceptable limits.
225 225
Tire Inflation Tire Inflation

Proper tire inflation pressures ensure maximum mileage and overall Proper tire inflation pressures ensure maximum mileage and overall
tire performance. Consult the specific tire manufacturer’s books for tire performance. Consult the specific tire manufacturer’s books for
correct inflation pressures per load, or refer to the vehicle safety correct inflation pressures per load, or refer to the vehicle safety
certification label. certification label.
Never operate a vehicle with underinflated (or Never operate a vehicle with underinflated (or
overloaded) tires, as this condition will cause overloaded) tires, as this condition will cause
excessive heat build-up which can result in excessive heat build-up which can result in
sudden tire destruction, property damage and sudden tire destruction, property damage and
personal injury. personal injury.
Tire Rotation Tire Rotation

Radial tires should be rotated only when necessary. If the tires are Radial tires should be rotated only when necessary. If the tires are
wearing evenly, there is no need to rotate. If irregular wear becomes wearing evenly, there is no need to rotate. If irregular wear becomes
apparent, or if wear rate on the tires is perceptively different (from axle apparent, or if wear rate on the tires is perceptively different (from axle
to axle or left side to right side of vehicle), then the tires should be to axle or left side to right side of vehicle), then the tires should be
rotated in such a manner as to alleviate the condition. rotated in such a manner as to alleviate the condition.
Some tires have tread that is uni-directional; consult Some tires have tread that is uni-directional; consult
manufacturer product information. Other than these manufacturer product information. Other than these
specific tires, there is no restriction on criss-cross specific tires, there is no restriction on criss-cross
rotation or reversing direction. rotation or reversing direction.
226 226
Tire Wear and Driving Habits Tire Wear and Driving Habits
All tires will wear out faster when subject to high speeds, as well as All tires will wear out faster when subject to high speeds, as well as
hard cornering, rapid starts, sudden stops, frequent turning at high hard cornering, rapid starts, sudden stops, frequent turning at high
turning angles, and frequent driving on surfaces which are in poor turning angles, and frequent driving on surfaces which are in poor
condition. Surfaces with holes and rocks or other objects can damage condition. Surfaces with holes and rocks or other objects can damage
tires and cause axle misalignment. tires and cause axle misalignment.
Tire Loading Tire Loading

Consult the tire manufacturer’s data book for complete information on Consult the tire manufacturer’s data book for complete information on
the allowable loads for your tires. Load capacity may vary with inflation the allowable loads for your tires. Load capacity may vary with inflation
pressure, and the speed at which the tire will be used. Tires which are pressure, and the speed at which the tire will be used. Tires which are
loaded beyond their maximum allowable loads will build up excessive loaded beyond their maximum allowable loads will build up excessive
heat that will result in rapid wear and/or sudden tire destruction. heat that will result in rapid wear and/or sudden tire destruction.
For additional tire information (i.e., high-speed limits, For additional tire information (i.e., high-speed limits,
inflation pressures, etc.), consult the product inflation pressures, etc.), consult the product
information available through the specific tire information available through the specific tire
manufacturer. manufacturer.
227 227
TIRE SERVICING TIRE SERVICING
Safety precautions must be taken when handling Safety precautions must be taken when handling
truck tires. Particularly when servicing multi-piece truck tires. Particularly when servicing multi-piece
wheel rims, proper safety precautions must be wheel rims, proper safety precautions must be
observed. Failure to comply with the following observed. Failure to comply with the following
procedures may result in serious injury or death. procedures may result in serious injury or death.
When removing tire and wheel assemblies or rim and wheel When removing tire and wheel assemblies or rim and wheel
assemblies from the vehicle, set the spring brakes and chock the assemblies from the vehicle, set the spring brakes and chock the
wheels which are not being removed. Use a heavy-duty jack to raise wheels which are not being removed. Use a heavy-duty jack to raise
the vehicle. the vehicle.
Instruct all tire and rim handling personnel on how to mount tires safely. Instruct all tire and rim handling personnel on how to mount tires safely.
Completely deflate the tires by removing the valve core before Completely deflate the tires by removing the valve core before
disassembling the tire from the rim. disassembling the tire from the rim.
Use proper tools to mount and demount the tires. Use proper tools to mount and demount the tires.
Use approved rust-retarding compounds to keep rims clean and free Use approved rust-retarding compounds to keep rims clean and free
from rust and corrosion. from rust and corrosion.
Use the correct size rim for the specified tire. Use the correct size rim for the specified tire.
Avoid rim damage when changing the tires. Avoid rim damage when changing the tires.
Examine the inside of the tire before mounting. Dry thoroughly if any Examine the inside of the tire before mounting. Dry thoroughly if any
moisture is found. moisture is found.
Use proper tubes and flaps with radial tires. Use proper tubes and flaps with radial tires.
Use the correct tire lubricant sparingly, especially in radial tire Use the correct tire lubricant sparingly, especially in radial tire
application, to minimize the possibility of fluid entering the tire. application, to minimize the possibility of fluid entering the tire.
Install the side or lock ring splits directly opposite (180 degrees) the Install the side or lock ring splits directly opposite (180 degrees) the
valve stem slot. valve stem slot.
228 228
Failure to follow proper safety precautions when Failure to follow proper safety precautions when
servicing multi-piece wheel rims may result in servicing multi-piece wheel rims may result in
serious injury or death. serious injury or death.
DO NOT over-inflate the tires. DO NOT over-inflate the tires.
DO NOT overload the rims. DO NOT overload the rims.
DO NOT remove the tire from the rim before completely deflating. DO NOT remove the tire from the rim before completely deflating.
DO NOT attempt to correct seating of the side and lock rings by DO NOT attempt to correct seating of the side and lock rings by
hammering while the tire is inflated. DEFLATE THE TIRE FIRST. hammering while the tire is inflated. DEFLATE THE TIRE FIRST.
DO NOT use corroded, damaged or distorted rims, rings or trim parts. DO NOT use corroded, damaged or distorted rims, rings or trim parts.
DO NOT fail to identify different makes of similar clamps; paint each DO NOT fail to identify different makes of similar clamps; paint each
make a different color. make a different color.
DO NOT use petroleum oil or grease on tire beads or rims. They will DO NOT use petroleum oil or grease on tire beads or rims. They will
ruin the tires. ruin the tires.
DO NOT use mismatched side and lock rings. DO NOT use mismatched side and lock rings.
DO NOT inflate the tires before all side and lock rings are in place. DO NOT inflate the tires before all side and lock rings are in place.
DO NOT inflate the tire unless it is placed in a safety cage or a portable DO NOT inflate the tire unless it is placed in a safety cage or a portable
lock ring guard. lock ring guard.
229 229
DRIVELINE RETARDER DRIVELINE RETARDER

At each D inspection, the driveline retarder coil-to-rotor air gap should At each D inspection, the driveline retarder coil-to-rotor air gap should
be measured and adjusted as required. If the coil-to-rotor air gap is too be measured and adjusted as required. If the coil-to-rotor air gap is too
small, contact between moving and non-moving components can small, contact between moving and non-moving components can
cause damage. If the air gap is too large, performance and efficiency of cause damage. If the air gap is too large, performance and efficiency of
the driveline retarder will be reduced. Measure the coil-to-rotor air gap the driveline retarder will be reduced. Measure the coil-to-rotor air gap
as follows: as follows:
1. At the inner rotor, use a thickness gauge to determine the air gap 1. At the inner rotor, use a thickness gauge to determine the air gap
between the coil pole shoe and the rotor. between the coil pole shoe and the rotor.
81 81

Figure 81 — Measuring Air Gap Figure 81 — Measuring Air Gap
1. Inner Rotor 2. Coil Pole Shoe Plate 1. Inner Rotor 2. Coil Pole Shoe Plate
2. Measure the gap at locations A, B, C and D, equally spaced 2. Measure the gap at locations A, B, C and D, equally spaced
(every other coil) around the rotor. (every other coil) around the rotor.
230 230
82 82

Figure 82 — Measure Air Gap at Four Locations Figure 82 — Measure Air Gap at Four Locations
3. Measurements should be within the 1.397–1.499 mm 3. Measurements should be within the 1.397–1.499 mm
(0.055–0.059 inch) range. Calculate the average air gap from the (0.055–0.059 inch) range. Calculate the average air gap from the
measurements taken at the four coils (locations A, B, C and D). measurements taken at the four coils (locations A, B, C and D).
The result will be the amount of shim thickness that must be The result will be the amount of shim thickness that must be
added or removed to bring air gap within the specified range. added or removed to bring air gap within the specified range.
4. Repeat the above procedures for the four coil locations at the 4. Repeat the above procedures for the four coil locations at the
outer rotor. outer rotor.
For procedures on adding or removing shims, refer to the Driveline For procedures on adding or removing shims, refer to the Driveline
Retarder Service Manual, 13-901. Retarder Service Manual, 13-901.
231 231
AIR BRAKE SYSTEM AIR BRAKE SYSTEM

Dual Circuit Brake System Function Test Dual Circuit Brake System Function Test
The following Dual Circuit Brake System Function Test should be The following Dual Circuit Brake System Function Test should be
performed at each C and D inspection interval, or after any air system performed at each C and D inspection interval, or after any air system
service procedures that involve disconnecting and reconnecting air service procedures that involve disconnecting and reconnecting air
lines where incorrect reconnection, such as the treadle valve, is a lines where incorrect reconnection, such as the treadle valve, is a
possibility. possibility.
1. Block the wheels to prevent the vehicle from moving. 1. Block the wheels to prevent the vehicle from moving.
2. Start the engine and build air system pressure to governor cutout. 2. Start the engine and build air system pressure to governor cutout.
3. Stop the engine. 3. Stop the engine.
4. Completely drain one air reservoir. 4. Completely drain one air reservoir.
5. Release the parking brakes. 5. Release the parking brakes.
6. Apply and hold the treadle valve. 6. Apply and hold the treadle valve.
7. Have an assistant check for proper results by observing the 7. Have an assistant check for proper results by observing the
movement of the slack adjusters as indicated below: movement of the slack adjusters as indicated below:
TRUCK: TRUCK:
앫 The brakes on the rear drive axle(s) should always apply as 앫 The brakes on the rear drive axle(s) should always apply as
indicated by movement of the slack adjuster. indicated by movement of the slack adjuster.
앫 The low-air warning buzzer and warning lamp should 앫 The low-air warning buzzer and warning lamp should
activate for at least two of the tests. activate for at least two of the tests.
TRACTOR: TRACTOR:
앫 The brakes on either the steering axle or the rear drive 앫 The brakes on either the steering axle or the rear drive
axle(s) should always apply as indicated by movement of axle(s) should always apply as indicated by movement of
the slack adjuster. the slack adjuster.
앫 The low-air warning buzzer and warning lamp should 앫 The low-air warning buzzer and warning lamp should
activate for at least two of the tests. activate for at least two of the tests.
8. Repeat the above procedures for the remaining air reservoirs (do 8. Repeat the above procedures for the remaining air reservoirs (do
not include air reservoirs for air starter if so equipped). not include air reservoirs for air starter if so equipped).
232 232
Long Stroke Chambers Long Stroke Chambers

Prior to 1/27/97, type 24 long stroke brake chambers were standard Prior to 1/27/97, type 24 long stroke brake chambers were standard
equipment on 34,000 to 44,000 lbs. rear axle suspensions, with type equipment on 34,000 to 44,000 lbs. rear axle suspensions, with type
30 brake chambers as an available option. After 1/27/97, type 30 brake 30 brake chambers as an available option. After 1/27/97, type 30 brake
chambers became the standard chamber on 34,000 to 44,000 lbs. rear chambers became the standard chamber on 34,000 to 44,000 lbs. rear
axle suspensions. axle suspensions.
The long stroke concept provides increased stroke to reduce The long stroke concept provides increased stroke to reduce
adjustment frequency, improved service chamber power, increased adjustment frequency, improved service chamber power, increased
spring force for parking, and the use of smaller chambers while still spring force for parking, and the use of smaller chambers while still
developing adequate braking force. developing adequate braking force.
There is a difference in diaphragm configuration between the long There is a difference in diaphragm configuration between the long
stroke and standard chambers. The diaphragm used in the long stroke stroke and standard chambers. The diaphragm used in the long stroke
chamber has a depth of 38.8 mm (1.53 inches), while the standard chamber has a depth of 38.8 mm (1.53 inches), while the standard
diaphragm has a depth of 31.8 mm (1.25 inches). Stroke length is diaphragm has a depth of 31.8 mm (1.25 inches). Stroke length is
63.5 mm (2.50 inches) for long stroke chambers and 57.2 mm 63.5 mm (2.50 inches) for long stroke chambers and 57.2 mm
(2.25 inches) for the standard stroke chambers. (2.25 inches) for the standard stroke chambers.
The standard stroke diaphragm must not be installed in the long stroke The standard stroke diaphragm must not be installed in the long stroke
chamber. To prevent confusion and/or mismatch of parts, both the chamber. To prevent confusion and/or mismatch of parts, both the
diaphragm and housing(s) are identified by prominent markings. diaphragm and housing(s) are identified by prominent markings.
233 233
Long Stroke Identification Long Stroke Identification

83 83
Figure 83 — Long Stroke Identification Figure 83 — Long Stroke Identification
234 234
BRAKE ADJUSTMENT BRAKE ADJUSTMENT

Cam Brake Adjustment Cam Brake Adjustment
PROCEDURE FOR CHECKING PUSH ROD TRAVEL PROCEDURE FOR CHECKING PUSH ROD TRAVEL
1. With the brakes released, measure the distance between the flat 1. With the brakes released, measure the distance between the flat
surface of the brake chamber to the center of the push rod clevis surface of the brake chamber to the center of the push rod clevis
pin. (If the chassis is equipped with Haldex automatic slack pin. (If the chassis is equipped with Haldex automatic slack
adjusters, measure to the far side of the clevis pin hole.) adjusters, measure to the far side of the clevis pin hole.)
84 84
Figure 84 — Brakes Released Measurement Figure 84 — Brakes Released Measurement

2. Make and hold a full brake treadle application. 2. Make and hold a full brake treadle application.
3. With the brakes applied, again measure the distance between the 3. With the brakes applied, again measure the distance between the
flat surface of the brake chamber to the center of the push rod flat surface of the brake chamber to the center of the push rod
clevis pin (far end of the clevis pin hole for Haldex automatic slack clevis pin (far end of the clevis pin hole for Haldex automatic slack
adjusters). adjusters).
85 85
Figure 85 — Brakes Applied Measurement Figure 85 — Brakes Applied Measurement
235 235
4. Subtract the measurement made with the brakes released from 4. Subtract the measurement made with the brakes released from
the measurement made with the brakes applied. The difference is the measurement made with the brakes applied. The difference is
the stroke. the stroke.
5. Compare the stroke measurement with the maximum stroke 5. Compare the stroke measurement with the maximum stroke
shown in the last column of the chart below. shown in the last column of the chart below.
PUSH ROD TRAVEL SPECIFICATIONS PUSH ROD TRAVEL SPECIFICATIONS
Effective Overall Maximum Applied Effective Overall Maximum Applied

Chamber Diaphragm Area Diameter Stroke mm Chamber Diaphragm Area Diameter Stroke mm
Size (Sq. In.) Inches (Inches) Size (Sq. In.) Inches (Inches)
9— 9 5-1/4 34.9 (1-3/8) 9— 9 5-1/4 34.9 (1-3/8)
12 — 12 5-11/16 34.9 (1-3/8) 12 — 12 5-11/16 34.9 (1-3/8)
16 — 16 6-3/8 44.4 (1-3/4) 16 — 16 6-3/8 44.4 (1-3/4)
20 — 20 6-13/16 44.4 (1-3/4) 20 — 20 6-13/16 44.4 (1-3/4)
24 — 24 7-1/4 44.4 (1-3/4) 24 — 24 7-1/4 44.4 (1-3/4)
24L — 24 7-1/4 50.8 (2) 24L — 24 7-1/4 50.8 (2)
30 — 30 8-1/8 50.8 (2) 30 — 30 8-1/8 50.8 (2)
36 — 36 9 57.1 (2-1/4) 36 — 36 9 57.1 (2-1/4)
Proper brake adjustment must be maintained for Proper brake adjustment must be maintained for
the safe operation of your truck. the safe operation of your truck.
236 236
Raise the axle to be adjusted and support on Raise the axle to be adjusted and support on
safety stands. safety stands.
앫 Support front axle under the axle housing or 앫 Support front axle under the axle housing or
center of axle. center of axle.
앫 Support rear axle under the lower spring 앫 Support rear axle under the lower spring
trunnion. trunnion.
Chock the wheels that remain on the ground. Chock the wheels that remain on the ground.
Release the parking brake while adjusting the Release the parking brake while adjusting the
brakes. brakes.
MANUAL SLACK ADJUSTERS MANUAL SLACK ADJUSTERS

Adjust the brakes whenever the push rod-applied stroke exceeds the Adjust the brakes whenever the push rod-applied stroke exceeds the
maximum allowable stroke as given in the table on page 236. maximum allowable stroke as given in the table on page 236.
86 86
Figure 86 — Manual Slack Adjuster Figure 86 — Manual Slack Adjuster
Position the wrench over the adjusting screw and depress the adjusting Position the wrench over the adjusting screw and depress the adjusting
lock sleeve BEFORE attempting to turn the adjusting screw. With the lock sleeve BEFORE attempting to turn the adjusting screw. With the
brake chamber push rod in the released position, turn the adjusting brake chamber push rod in the released position, turn the adjusting
screw, while rotating the wheel, until the brake linings are against the screw, while rotating the wheel, until the brake linings are against the
brake drum. Back off the adjusting screw until the wheel rotates freely. brake drum. Back off the adjusting screw until the wheel rotates freely.
When the adjustment is complete, be sure the locking sleeve is When the adjustment is complete, be sure the locking sleeve is
returned to its locked position by allowing the sleeve to engage the hex returned to its locked position by allowing the sleeve to engage the hex
head of the adjusting screw. head of the adjusting screw.
237 237
Be sure all wheels are on the ground when the brakes Be sure all wheels are on the ground when the brakes
are applied. are applied.
After proper adjustment, apply the brakes. The slack adjuster arm and After proper adjustment, apply the brakes. The slack adjuster arm and
brake chamber push rod should form an angle of 90 degrees. The brake chamber push rod should form an angle of 90 degrees. The
brake chamber push rod should also form a 90-degree angle with the brake chamber push rod should also form a 90-degree angle with the
flat mounting surface of the brake chamber. All slack adjusters on the flat mounting surface of the brake chamber. All slack adjusters on the
vehicle must be at the same angle. vehicle must be at the same angle.
87 87
Figure 87 — Proper Slack Adjustment Figure 87 — Proper Slack Adjustment
238 238
AUTOMATIC SLACK ADJUSTERS AUTOMATIC SLACK ADJUSTERS

Automatic slack adjusters are designed to automatically maintain Automatic slack adjusters are designed to automatically maintain
proper brake chamber stroke and compensate for brake lining wear proper brake chamber stroke and compensate for brake lining wear
during normal use. The only time automatic slack adjusters will need during normal use. The only time automatic slack adjusters will need
adjustment is during initial installation, removal or to back off the brake adjustment is during initial installation, removal or to back off the brake
shoes during brake work such as brake shoe relining, brake drum shoes during brake work such as brake shoe relining, brake drum
reconditioning, etc. DO NOT rely on automatic slack adjusters to take reconditioning, etc. DO NOT rely on automatic slack adjusters to take
up excessive initial clearance. For procedures to adjust automatic slack up excessive initial clearance. For procedures to adjust automatic slack
adjusters, refer to the Air and Brake System Service Manual, 16-104. adjusters, refer to the Air and Brake System Service Manual, 16-104.
When push rod travel exceeds specifications (as given in the table on When push rod travel exceeds specifications (as given in the table on
page 236) on a vehicle equipped with automatic slack adjusters, a page 236) on a vehicle equipped with automatic slack adjusters, a
mechanical problem with the slack adjuster, brake components or mechanical problem with the slack adjuster, brake components or
improper installation of the slack adjuster is indicated. If brakes are improper installation of the slack adjuster is indicated. If brakes are
found to be out of adjustment, the vehicle must be taken to the nearest found to be out of adjustment, the vehicle must be taken to the nearest
repair facility as soon as possible to have the problem investigated and repair facility as soon as possible to have the problem investigated and
corrected. corrected.
Automatic slack adjusters MUST NOT be manually Automatic slack adjusters MUST NOT be manually
adjusted in an effort to correct excessive push rod adjusted in an effort to correct excessive push rod
stroke, as this condition indicates that a problem stroke, as this condition indicates that a problem
exists with the automatic adjuster, installation of exists with the automatic adjuster, installation of
the automatic slack adjuster or problems related the automatic slack adjuster or problems related
to components of the foundation brakes. These to components of the foundation brakes. These
conditions will not be corrected by manually conditions will not be corrected by manually
adjusting the automatic slack adjusters. adjusting the automatic slack adjusters.
Manual adjustment of automatic slack adjusters is Manual adjustment of automatic slack adjusters is
a dangerous practice that could result in serious a dangerous practice that could result in serious
consequences. This practice gives the vehicle consequences. This practice gives the vehicle
operator a false sense of security about the operator a false sense of security about the
effectiveness of the brakes, and the brakes will effectiveness of the brakes, and the brakes will
likely soon be out of adjustment again. likely soon be out of adjustment again.
Before attempting to turn the manual adjusting nut on Before attempting to turn the manual adjusting nut on
ArvinMeritor™ automatic slack adjusters, the pawl ArvinMeritor™ automatic slack adjusters, the pawl
must first be removed or damage to the pawl teeth must first be removed or damage to the pawl teeth
may result. may result.
239 239
CAB MOUNT MAINTENANCE — LEU AND MRU MODELS CAB MOUNT MAINTENANCE — LEU AND MRU MODELS
CAB MOUNT MAINTENANCE — LEU AND MRU CAB MOUNT MAINTENANCE — LEU AND MRU
MODELS MODELS
Cab Mounting Maintenance and Alignment Adjustment — Cab Mounting Maintenance and Alignment Adjustment —
LEU and MRU Model Chassis LEU and MRU Model Chassis
At each C and D inspection interval, cab rear mounting alignment must At each C and D inspection interval, cab rear mounting alignment must
be checked and adjusted, if necessary, and the anti-vibration pads on be checked and adjusted, if necessary, and the anti-vibration pads on
the frame-mounted V-brackets must be inspected. Replace any pads the frame-mounted V-brackets must be inspected. Replace any pads
that are missing or damaged. that are missing or damaged.
88 88

Figure 88 — Cab Mount Anti-Vibration Pads Figure 88 — Cab Mount Anti-Vibration Pads
1. Anti-Vibration Pads 2. V-Bracket 1. Anti-Vibration Pads 2. V-Bracket
240 240
CAB MOUNT/LATCH ALIGNMENT — LEU MODELS CAB MOUNT/LATCH ALIGNMENT — LEU MODELS
To check cab mount alignment, raise the cab, apply a generous To check cab mount alignment, raise the cab, apply a generous
amount of white lithium grease to all four anti-vibration pads on the amount of white lithium grease to all four anti-vibration pads on the
V-bracket, then lower the cab until the cab latch hook fully engages the V-bracket, then lower the cab until the cab latch hook fully engages the
V-block. As the hook engages, observe that it enters the block without V-block. As the hook engages, observe that it enters the block without
contacting the edges. Raise the cab and examine the grease on the contacting the edges. Raise the cab and examine the grease on the
anti-vibration pads for uniform contact with the mating surfaces of the anti-vibration pads for uniform contact with the mating surfaces of the
V-block. Also, when raising the cab, make sure there is no contact or V-block. Also, when raising the cab, make sure there is no contact or
interference between the cab latch hook and the cab V-block. On the interference between the cab latch hook and the cab V-block. On the
right-hand side of the vehicle, make sure the cab latch hook does not right-hand side of the vehicle, make sure the cab latch hook does not
contact the turbocharger inlet tube when fully opened. These checks contact the turbocharger inlet tube when fully opened. These checks
must be performed on each side of the vehicle. must be performed on each side of the vehicle.
241 241
ADJUSTMENT ADJUSTMENT
The mounting bolt holes in the frame-mounted cab mount bracket, The mounting bolt holes in the frame-mounted cab mount bracket,
latch cylinder mounting plate and cab rear mount V-block are all slotted latch cylinder mounting plate and cab rear mount V-block are all slotted
for adjustment purposes. The frame-mounted bracket can be tilted fore for adjustment purposes. The frame-mounted bracket can be tilted fore
and aft along the vertical centerline of the bracket, and the cab- and aft along the vertical centerline of the bracket, and the cab-
mounted V-block can be tilted up and down along the horizontal mounted V-block can be tilted up and down along the horizontal
centerline of the block so that uniform contact between the V-block and centerline of the block so that uniform contact between the V-block and
anti-vibration pads can be obtained. The latch cylinder can be moved in anti-vibration pads can be obtained. The latch cylinder can be moved in
the inboard and outboard directions so that uniform side-to-side the inboard and outboard directions so that uniform side-to-side
contact can be obtained. contact can be obtained.
89 89

Figure 89 — Adjustment Points — LEU Model Cab Figure 89 — Adjustment Points — LEU Model Cab
1. Tilt Up/Down 4. Loosen Four Bolts 1. Tilt Up/Down 4. Loosen Four Bolts
2. Loosen Eight Bolts 5. Tilt Fore/Aft 2. Loosen Eight Bolts 5. Tilt Fore/Aft
3. Move Inboard/Outboard 6. Loosen Four Bolts 3. Move Inboard/Outboard 6. Loosen Four Bolts
242 242
The front inner two mounting bolts of the V-block are The front inner two mounting bolts of the V-block are
located behind a body panel. The panel must be located behind a body panel. The panel must be
removed to access these two bolts. removed to access these two bolts.
If the grease print on the anti-vibration pads shows that the V-block is If the grease print on the anti-vibration pads shows that the V-block is
not sitting evenly in the V-bracket in the front-to-back directions (i.e., not sitting evenly in the V-bracket in the front-to-back directions (i.e.,
heavy contact against the front two pads and light contact against the heavy contact against the front two pads and light contact against the
rear two pads), loosen the frame bracket and V-block mounting bolts rear two pads), loosen the frame bracket and V-block mounting bolts
and tilt the bracket and V-block as required to obtain uniform contact. If and tilt the bracket and V-block as required to obtain uniform contact. If
the grease print shows that the V-block is not contacting the anti- the grease print shows that the V-block is not contacting the anti-
vibration pads in the side-to-side directions (i.e., heavy contact against vibration pads in the side-to-side directions (i.e., heavy contact against
the inner two pads and light contact against the outer two pads), the inner two pads and light contact against the outer two pads),
loosen the latch cylinder mounting bolts and move the cylinder loosen the latch cylinder mounting bolts and move the cylinder
assembly inboard or outboard as necessary to obtain uniform contact. assembly inboard or outboard as necessary to obtain uniform contact.
After completing the alignment adjustments, tighten the mounting After completing the alignment adjustments, tighten the mounting
bracket fasteners as follows: bracket fasteners as follows:
앫 Cab Latch Cylinder Mounting Plate — 34 N폷m (25 lb-ft) 앫 Cab Latch Cylinder Mounting Plate — 34 N폷m (25 lb-ft)
앫 Frame-Mounted Cab Mount Bracket — 100 N폷m (74 lb-ft) 앫 Frame-Mounted Cab Mount Bracket — 100 N폷m (74 lb-ft)
앫 Cab Rear Mount V-Block — 65 N폷m (48 lb-ft) 앫 Cab Rear Mount V-Block — 65 N폷m (48 lb-ft)
If the latch hook on the right-hand side of the chassis contacts the If the latch hook on the right-hand side of the chassis contacts the
turbocharger inlet tube, loosen the inlet tube clamps and rotate the turbocharger inlet tube, loosen the inlet tube clamps and rotate the
tube inboard, away from the latch hook. tube inboard, away from the latch hook.
243 243
90 90

Figure 90 — Adjust Inlet Tube to Avoid Contact with Cab Latch Figure 90 — Adjust Inlet Tube to Avoid Contact with Cab Latch
1. Avoid Contact Between Tube and Latch 1. Avoid Contact Between Tube and Latch
CAB MOUNT/LATCH ALIGNMENT — MRU MODELS CAB MOUNT/LATCH ALIGNMENT — MRU MODELS
To check cab mount alignment, raise the cab, apply a generous To check cab mount alignment, raise the cab, apply a generous
amount of white lithium grease to all four anti-vibration pads on the amount of white lithium grease to all four anti-vibration pads on the
V-bracket, then lower the cab until the cab latch hook fully engages the V-bracket, then lower the cab until the cab latch hook fully engages the
V-block. As the hook engages, observe that it enters the block without V-block. As the hook engages, observe that it enters the block without
contacting the edges. Raise the cab and examine the grease on the contacting the edges. Raise the cab and examine the grease on the
anti-vibration pads for uniform contact with the mating surfaces of the anti-vibration pads for uniform contact with the mating surfaces of the
V-block. Also, when raising the cab, make sure there is no contact or V-block. Also, when raising the cab, make sure there is no contact or
interference between the cab latch hook and the cab V-block. These interference between the cab latch hook and the cab V-block. These
checks must be performed on each side of the vehicle. checks must be performed on each side of the vehicle.
244 244
ADJUSTMENT ADJUSTMENT
The bolt holes in the latch cylinder mounting plate and the cab rear The bolt holes in the latch cylinder mounting plate and the cab rear
mount V-block are slotted for adjustment purposes. The V-block can be mount V-block are slotted for adjustment purposes. The V-block can be
moved fore and aft along the horizontal centerline of the cab to ensure moved fore and aft along the horizontal centerline of the cab to ensure
the cab latch hook enters the slot in the V-block without interference. the cab latch hook enters the slot in the V-block without interference.
The latch cylinder assembly can be moved in the inboard and outboard The latch cylinder assembly can be moved in the inboard and outboard
directions (relative to the frame) so that uniform side-to-side contact on directions (relative to the frame) so that uniform side-to-side contact on
the anti-vibration pads can be obtained. The mounting bolt holes for the anti-vibration pads can be obtained. The mounting bolt holes for
the frame-mounted cab mount bracket are not slotted. For uniform the frame-mounted cab mount bracket are not slotted. For uniform
front-to-back contact on the anti-vibration pads, it will be necessary to front-to-back contact on the anti-vibration pads, it will be necessary to
loosen the two mounting bolts and tilt the bracket as necessary to loosen the two mounting bolts and tilt the bracket as necessary to
obtain uniform contact. obtain uniform contact.
91 91

Figure 91 — Adjustment Points — MRU Models Figure 91 — Adjustment Points — MRU Models
1. Move Fore/Aft 4. Loosen Four Bolts 1. Move Fore/Aft 4. Loosen Four Bolts
2. Loosen Eight Bolts 5. Tilt Fore/Aft 2. Loosen Eight Bolts 5. Tilt Fore/Aft
3. Move Inboard/Outboard 6. Loosen Six Bolts 3. Move Inboard/Outboard 6. Loosen Six Bolts
245 245
If the grease print shows that the cab rear mount V-block is not If the grease print shows that the cab rear mount V-block is not
contacting the anti-vibration pads evenly in the fore and aft directions contacting the anti-vibration pads evenly in the fore and aft directions
(i.e., heavy contact against the forward two pads and light contact (i.e., heavy contact against the forward two pads and light contact
against the rearward two pads), loosen the frame-mounted cab mount against the rearward two pads), loosen the frame-mounted cab mount
bracket and tilt the bracket as necessary to obtain uniform contact. If bracket and tilt the bracket as necessary to obtain uniform contact. If
the grease print shows that the cab rear mount V-block is not the grease print shows that the cab rear mount V-block is not
contacting the anti-vibration pads evenly in the side-to-side directions contacting the anti-vibration pads evenly in the side-to-side directions
(i.e., heavy contact against the inner two pads and light contact against (i.e., heavy contact against the inner two pads and light contact against
the outer two pads), loosen the latch cylinder mounting bolts and move the outer two pads), loosen the latch cylinder mounting bolts and move
the cylinder assembly inboard or outboard as necessary to obtain the cylinder assembly inboard or outboard as necessary to obtain
uniform contact. After performing the adjustments to the frame- uniform contact. After performing the adjustments to the frame-
mounted bracket and the cab latch cylinder mounting plate, verify that mounted bracket and the cab latch cylinder mounting plate, verify that
the latch hook is centered in the V-block when the cab is completely the latch hook is centered in the V-block when the cab is completely
lowered and does not contact the latch hook as the cab is being raised lowered and does not contact the latch hook as the cab is being raised
or lowered. If the latch book is not centered or it contacts the V-block, or lowered. If the latch book is not centered or it contacts the V-block,
loosen the eight rear cab mount V-block mounting bolts and move the loosen the eight rear cab mount V-block mounting bolts and move the
block fore and aft as required. block fore and aft as required.
After completing the alignment adjustments, tighten the mounting After completing the alignment adjustments, tighten the mounting
bracket fasteners as follows: bracket fasteners as follows:
앫 Cab Latch Cylinder Mounting Plate — 34 N폷m (25 lb-ft) 앫 Cab Latch Cylinder Mounting Plate — 34 N폷m (25 lb-ft)
앫 Frame-Mounted Cab Mount Bracket — 100 N폷m (74 lb-ft) 앫 Frame-Mounted Cab Mount Bracket — 100 N폷m (74 lb-ft)
앫 Cab Rear Mount V-Block — 65 N폷m (48 lb-ft) 앫 Cab Rear Mount V-Block — 65 N폷m (48 lb-ft)
246 246
CLUTCH ADJUSTMENT CLUTCH ADJUSTMENT

For the clutch to release properly, the release bearing must travel For the clutch to release properly, the release bearing must travel
12.7 to 14.3 mm (1/2″ to 9/16″), there must be 3.2 mm (1/8″) of 12.7 to 14.3 mm (1/2″ to 9/16″), there must be 3.2 mm (1/8″) of
clearance between the clutch release yoke and the release bearing clearance between the clutch release yoke and the release bearing
wear pads (free travel) and clutch brake squeeze must occur within the wear pads (free travel) and clutch brake squeeze must occur within the
last 6.35 to 9.53 mm (1/4″ to 3/8″) of clutch pedal travel. last 6.35 to 9.53 mm (1/4″ to 3/8″) of clutch pedal travel.
92 92

! !

Figure 92 — Release Bearing Travel Figure 92 — Release Bearing Travel
Through normal use, the friction surfaces of the clutch wear, resulting Through normal use, the friction surfaces of the clutch wear, resulting
in an increase in release bearing travel. As bearing travel increases, in an increase in release bearing travel. As bearing travel increases,
clearance between the release yoke and wear pads decreases, which clearance between the release yoke and wear pads decreases, which
becomes evident as a decrease in clutch pedal free play in the cab. becomes evident as a decrease in clutch pedal free play in the cab.
When a decrease in free play is noticed, adjustment of the clutch is When a decrease in free play is noticed, adjustment of the clutch is
necessary to maintain proper clutch release operation. An improperly necessary to maintain proper clutch release operation. An improperly
adjusted clutch will slip and eventually burn out. adjusted clutch will slip and eventually burn out.
When clutch pedal free play in the cab decreases to 12.7 mm (1/2″), When clutch pedal free play in the cab decreases to 12.7 mm (1/2″),
the clutch must be adjusted to ensure proper clutch operation. Clutch the clutch must be adjusted to ensure proper clutch operation. Clutch
adjustment must be performed in the following order: adjustment must be performed in the following order:
앫 Verify and adjust clutch brake squeeze 앫 Verify and adjust clutch brake squeeze
앫 Adjust clutch pedal free play 앫 Adjust clutch pedal free play
앫 Verify clutch release yoke and release bearing free travel 앫 Verify clutch release yoke and release bearing free travel
247 247
Verify and Adjust Clutch Brake Squeeze Verify and Adjust Clutch Brake Squeeze
Verify that clutch brake squeeze occurs within the last 6.35 to 9.53 mm Verify that clutch brake squeeze occurs within the last 6.35 to 9.53 mm
(1/4″ to 3/8″) of clutch pedal travel. Clutch brake squeeze is verified as (1/4″ to 3/8″) of clutch pedal travel. Clutch brake squeeze is verified as
follows: follows:
93 93

# #
" "

! !

Figure 93 — Verify Clutch Brake Squeeze Figure 93 — Verify Clutch Brake Squeeze
1. Remove the inspection cover from the transmission bell housing. 1. Remove the inspection cover from the transmission bell housing.
2. Insert a 0.254 mm (0.010-inch) thickness gauge between the rear 2. Insert a 0.254 mm (0.010-inch) thickness gauge between the rear
face of the clutch release bearing and the clutch brake. face of the clutch release bearing and the clutch brake.
3. Have an assistant fully depress the clutch pedal and then slowly 3. Have an assistant fully depress the clutch pedal and then slowly
release the pedal. Tell the assistant to stop releasing the pedal as release the pedal. Tell the assistant to stop releasing the pedal as
soon as the thickness gauge can be pulled from between the soon as the thickness gauge can be pulled from between the
release bearing and the clutch brake. release bearing and the clutch brake.
4. Measure the distance between the pedal and the floor. Clutch 4. Measure the distance between the pedal and the floor. Clutch
brake must occur within the last 6.35 to 9.53 mm (1/4″ to 3/8″) of brake must occur within the last 6.35 to 9.53 mm (1/4″ to 3/8″) of
pedal travel. pedal travel.
248 248
If clutch brake squeeze is not within specifications, adjust as If clutch brake squeeze is not within specifications, adjust as
follows: follows:
94 94
Figure 94 — Clutch Brake Squeeze Adjustment Figure 94 — Clutch Brake Squeeze Adjustment
5. Loosen the clutch dog lock nut. 5. Loosen the clutch dog lock nut.
6. Loosen the adjusting bolt jam nut. 6. Loosen the adjusting bolt jam nut.
7. Turn the adjusting bolt to properly set clutch brake squeeze. 7. Turn the adjusting bolt to properly set clutch brake squeeze.
앫 Turning the adjusting bolt clockwise moves clutch brake 앫 Turning the adjusting bolt clockwise moves clutch brake
squeeze further from the end of pedal travel (increases squeeze further from the end of pedal travel (increases
dimension). dimension).
앫 Turning the adjusting bolt counterclockwise moves clutch 앫 Turning the adjusting bolt counterclockwise moves clutch
brake squeeze closer to the end of pedal travel (decreases brake squeeze closer to the end of pedal travel (decreases
dimension). dimension).
8. When clutch brake squeeze has been properly set, tighten the 8. When clutch brake squeeze has been properly set, tighten the
clutch dog lock bolt and the adjusting bolt jam nut. clutch dog lock bolt and the adjusting bolt jam nut.
249 249
Adjust Clutch Pedal Free Play Adjust Clutch Pedal Free Play
After verifying and adjusting clutch brake squeeze, clutch pedal free After verifying and adjusting clutch brake squeeze, clutch pedal free
play must be adjusted. MACK chassis utilize either a standard cable- play must be adjusted. MACK chassis utilize either a standard cable-
operated or a cable-operated air-assist clutch release system. Clutch operated or a cable-operated air-assist clutch release system. Clutch
pedal free play specifications for both release systems are as follows: pedal free play specifications for both release systems are as follows:
앫 Standard cable-operated clutch release system — 앫 Standard cable-operated clutch release system —
44.5 ± 6.4 mm (1-3/4 ± 1/4 inch) 44.5 ± 6.4 mm (1-3/4 ± 1/4 inch)
앫 Cable-operated air-assist clutch release system — 앫 Cable-operated air-assist clutch release system —
28.6 ± 6.4 mm (1-1/8 ± 1/4 inch) 28.6 ± 6.4 mm (1-1/8 ± 1/4 inch)
When clutch pedal free play is properly adjusted to the specifications When clutch pedal free play is properly adjusted to the specifications
listed, there will be approximately 3.2 mm (1/8″) of clearance between listed, there will be approximately 3.2 mm (1/8″) of clearance between
the clutch release yoke and the release bearing wear pads. the clutch release yoke and the release bearing wear pads.
For the air-assist clutch release system, the 28.6 ± 6.4 mm For the air-assist clutch release system, the 28.6 ± 6.4 mm
(1-1/8 ± 1/4 inch) of clutch pedal free play allows approximately (1-1/8 ± 1/4 inch) of clutch pedal free play allows approximately
76.2–96.5 mm (3 to 3-13/16 inch) of cylinder rod to be visible when 76.2–96.5 mm (3 to 3-13/16 inch) of cylinder rod to be visible when
measured from the cylinder body to the bottom of the rod end. This measured from the cylinder body to the bottom of the rod end. This
dimension provides the proper cable travel and ensures that the dimension provides the proper cable travel and ensures that the
cylinder will not bottom when the clutch pedal is pushed in (clutch cylinder will not bottom when the clutch pedal is pushed in (clutch
disengaged). disengaged).
Clutch pedal free play adjustments are performed by adjusting the Clutch pedal free play adjustments are performed by adjusting the
internal clutch ring. internal clutch ring.
250 250
95 95
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Figure 95 — Clutch Pedal Free Play Figure 95 — Clutch Pedal Free Play
251 251
Adjust clutch pedal free play as follows: Adjust clutch pedal free play as follows:
Spicer Solo™ 15-1/2 Inch Self-Adjusting Clutch Spicer Solo™ 15-1/2 Inch Self-Adjusting Clutch
The Spicer Solo™ self-adjusting clutch is designed to maintain proper The Spicer Solo™ self-adjusting clutch is designed to maintain proper
release bearing travel throughout the life of the clutch. The only time release bearing travel throughout the life of the clutch. The only time
adjustment of a Spicer Solo™ self-adjusting clutch should be required adjustment of a Spicer Solo™ self-adjusting clutch should be required
is at installation of a new clutch. Adjustment of the clutch is is at installation of a new clutch. Adjustment of the clutch is
accomplished by fully depressing the clutch pedal until the release accomplished by fully depressing the clutch pedal until the release
bearing contacts and “squeezes” the clutch brake, and then releasing bearing contacts and “squeezes” the clutch brake, and then releasing
the pedal a minimum of five times. This “release bearing to clutch the pedal a minimum of five times. This “release bearing to clutch
brake contact” ensures that the clutch release bearing travel is properly brake contact” ensures that the clutch release bearing travel is properly
set at 12.7 to 14.3 mm (1/2″ to 9/16″) and that the clearance between set at 12.7 to 14.3 mm (1/2″ to 9/16″) and that the clearance between
the release yoke and the release bearing wear pads is 3.2 mm (1/8″). the release yoke and the release bearing wear pads is 3.2 mm (1/8″).
Spicer Easy Pedal 15-1/2 Inch Angle Spring Clutch with Kwik- Spicer Easy Pedal 15-1/2 Inch Angle Spring Clutch with Kwik-
Adjust™ Component Adjust™ Component
1. Rotate the engine in the direction of normal rotation until the 1. Rotate the engine in the direction of normal rotation until the
Kwik-Adjust™ component is visible through the bell housing Kwik-Adjust™ component is visible through the bell housing
inspection hole. inspection hole.
2. Insert a 5/8″ socket or box wrench through the inspection hole 2. Insert a 5/8″ socket or box wrench through the inspection hole
and over the hex-headed bolt on the Kwik-Adjust™ component. and over the hex-headed bolt on the Kwik-Adjust™ component.
96 96
Figure 96 — Wrench on Kwik-Adjust™ Component Figure 96 — Wrench on Kwik-Adjust™ Component
252 252
On some clutches, the Kwik-Adjust™ component may On some clutches, the Kwik-Adjust™ component may
utilize a square-headed bolt which requires a 3/4″ utilize a square-headed bolt which requires a 3/4″
12-point wrench or socket. 12-point wrench or socket.
3. Have an assistant fully depress the clutch pedal (clutch 3. Have an assistant fully depress the clutch pedal (clutch
disengaged). disengaged).
4. Depress and turn the bolt in the direction of the arrow embossed 4. Depress and turn the bolt in the direction of the arrow embossed
on the clutch. on the clutch.
The clutch must be released before attempting to turn The clutch must be released before attempting to turn
the adjusting bolt. the adjusting bolt.
97 97
Figure 97 — Adjusting Clutch Ring Figure 97 — Adjusting Clutch Ring

앫 Turning the Kwik-Adjust™ component clockwise moves the 앫 Turning the Kwik-Adjust™ component clockwise moves the
release bearing away from the clutch (increases clutch release bearing away from the clutch (increases clutch
pedal free play). pedal free play).
앫 Turning the Kwik-Adjust™ component counterclockwise 앫 Turning the Kwik-Adjust™ component counterclockwise
moves the release bearing toward the clutch (decreases moves the release bearing toward the clutch (decreases
clutch pedal free play). clutch pedal free play).
253 253
The Kwik-Adjust™ component re-engages at each sixth turn, and The Kwik-Adjust™ component re-engages at each sixth turn, and
a flat of the hex-headed bolt will align with the flat on the edge of a flat of the hex-headed bolt will align with the flat on the edge of
the bracket. Kwik-Adjust™ components that utilize the 3/4″ the bracket. Kwik-Adjust™ components that utilize the 3/4″
square-headed bolt will re-engage at every 1/4 turn. square-headed bolt will re-engage at every 1/4 turn.
5. Measure clutch pedal free play in the cab. If not within 5. Measure clutch pedal free play in the cab. If not within
specifications, readjust the clutch ring as required. specifications, readjust the clutch ring as required.
ArvinMeritor™ 15-1/2 Inch Clutch ArvinMeritor™ 15-1/2 Inch Clutch

1. Rotate the engine in the direction of normal rotation until the 1. Rotate the engine in the direction of normal rotation until the
clutch adjustment lock plate is visible through the bell housing clutch adjustment lock plate is visible through the bell housing
inspection hole. inspection hole.
98 98
Figure 98 — Clutch Adjusting Lock Plate Figure 98 — Clutch Adjusting Lock Plate
2. Remove the screw and washer from the lock plate, and then 2. Remove the screw and washer from the lock plate, and then
remove the lock plate. remove the lock plate.
3. Have an assistant fully depress the clutch pedal (clutch released). 3. Have an assistant fully depress the clutch pedal (clutch released).
4. Using a universal clutch adjusting tool (tool No. J 36216) or a 4. Using a universal clutch adjusting tool (tool No. J 36216) or a
large screwdriver against the notches on the adjusting ring, turn large screwdriver against the notches on the adjusting ring, turn
the adjusting ring to move the release bearing as required to the adjusting ring to move the release bearing as required to
clutch pedal free play. Moving the adjusting ring one notch moves clutch pedal free play. Moving the adjusting ring one notch moves
the release bearing approximately 0.50 mm (0.020 inch). the release bearing approximately 0.50 mm (0.020 inch).
254 254
The clutch must be disengaged (clutch pedal pushed The clutch must be disengaged (clutch pedal pushed
to the floor) before attempting to turn the clutch to the floor) before attempting to turn the clutch
adjusting ring. adjusting ring.
99 99

Figure 99 — Adjusting Clutch Figure 99 — Adjusting Clutch

5. Measure clutch pedal free play in the cab. If not within 5. Measure clutch pedal free play in the cab. If not within
specifications, readjust as required. specifications, readjust as required.
6. When clutch pedal free play has been adjusted to proper 6. When clutch pedal free play has been adjusted to proper
specifications, reinstall the lock plate and tighten the capscrew to specifications, reinstall the lock plate and tighten the capscrew to
37 N폷m (27 lb-ft). 37 N폷m (27 lb-ft).
255 255
Verify Clutch Release Yoke and Release Bearing Travel Verify Clutch Release Yoke and Release Bearing Travel
After clutch brake squeeze and clutch pedal free play have been After clutch brake squeeze and clutch pedal free play have been
properly adjusted, verify that 3.2 mm (1/8″) of clearance exists between properly adjusted, verify that 3.2 mm (1/8″) of clearance exists between
the clutch release yoke and the release bearing wear pads, and that the clutch release yoke and the release bearing wear pads, and that
release bearing travel is between 12.7 to 14.3 mm (1/2″ and 9/16″). release bearing travel is between 12.7 to 14.3 mm (1/2″ and 9/16″).
Release bearing travel is the distance between the rear face of the Release bearing travel is the distance between the rear face of the
release bearing and the clutch brake. If not within specifications, release bearing and the clutch brake. If not within specifications,
inspect the clutch release system for a stretched cable, worn clevises, inspect the clutch release system for a stretched cable, worn clevises,
worn or missing rubber pedal stops, etc. Repair or replace components worn or missing rubber pedal stops, etc. Repair or replace components
as necessary, and then readjust the clutch. as necessary, and then readjust the clutch.
100 100

! !

Figure 100 — Measure Release Bearing Travel Figure 100 — Measure Release Bearing Travel
After completing the clutch adjustments, reinstall the transmission bell After completing the clutch adjustments, reinstall the transmission bell
housing inspection cover. housing inspection cover.
256 256
Clutch Assist Cylinder Filter Clutch Assist Cylinder Filter

The air-operated clutch assist release system consists of a cable- The air-operated clutch assist release system consists of a cable-
operated air regulator and a single-acting air cylinder. The air cylinder operated air regulator and a single-acting air cylinder. The air cylinder
contains an exhaust port at the “blind-end” of the cylinder where air contains an exhaust port at the “blind-end” of the cylinder where air
exhausts from the cylinder as the cylinder rod retracts, and is drawn exhausts from the cylinder as the cylinder rod retracts, and is drawn
into the cylinder when the cylinder rod extends. A sintered-bronze filter into the cylinder when the cylinder rod extends. A sintered-bronze filter
prevents contaminants from entering the exhaust port. The filter is prevents contaminants from entering the exhaust port. The filter is
located just below the coolant surge tank and is secured to the clutch located just below the coolant surge tank and is secured to the clutch
cable with plastic tie wraps. A plastic hose connects the filter to the cable with plastic tie wraps. A plastic hose connects the filter to the
assist cylinder exhaust port. If the clutch pedal feels “spongy,” or assist cylinder exhaust port. If the clutch pedal feels “spongy,” or
increased pedal effort is noticed, remove the filter from the exhaust increased pedal effort is noticed, remove the filter from the exhaust
port, clean in a suitable non-flammable solvent, blow dry with port, clean in a suitable non-flammable solvent, blow dry with
compressed air and reinstall. compressed air and reinstall.
101 101

Figure 101 — Clutch Assist Cylinder Filter Figure 101 — Clutch Assist Cylinder Filter
1. Sintered-Bronze Filter 1. Sintered-Bronze Filter
257 257
VALVE AND UNIT INJECTOR ADJUSTMENT VALVE AND UNIT INJECTOR ADJUSTMENT
VALVE AND UNIT INJECTOR ADJUSTMENT VALVE AND UNIT INJECTOR ADJUSTMENT
Initial Adjustment Initial Adjustment
An initial valve lash and unit injector pre-load check and adjustment An initial valve lash and unit injector pre-load check and adjustment
must be performed at the end of the first 200 000 km (125,000 miles), must be performed at the end of the first 200 000 km (125,000 miles),
or 12 months of service, whichever occurs first. or 12 months of service, whichever occurs first.
Regular Adjustment Regular Adjustment

After the initial valve adjustment, valve lash and unit injector pre-load After the initial valve adjustment, valve lash and unit injector pre-load
must be checked and adjusted at each 400 000 km (250,000 miles), or must be checked and adjusted at each 400 000 km (250,000 miles), or
24 month interval, whichever occurs first. 24 month interval, whichever occurs first.
Valve lash specifications can be found on the engine identification label Valve lash specifications can be found on the engine identification label
which is affixed to the left-hand side of the cylinder head cover at the which is affixed to the left-hand side of the cylinder head cover at the
front of the engine. For valve adjustment procedures, refer to the front of the engine. For valve adjustment procedures, refer to the
applicable engine service manual. applicable engine service manual.
258 258
BRAKE DIAGNOSTIC CHART BRAKE DIAGNOSTIC CHART

The following troubleshooting chart summarizes some common dual The following troubleshooting chart summarizes some common dual
braking system problems, probable causes and corrections. Use this braking system problems, probable causes and corrections. Use this
chart as a guide to service the dual brake system. chart as a guide to service the dual brake system.
CONDITION LOW AIR PRESSURE WARNING CONDITION LOW AIR PRESSURE WARNING
RED LIGHT DOES NOT GO OUT RED LIGHT DOES NOT GO OUT
AFTER STARTUP. AFTER STARTUP.
POSSIBLE CAUSE CORRECTION POSSIBLE CAUSE CORRECTION
1. Loss of one section of the dual 1. Observe dual pressure gauge to 1. Loss of one section of the dual 1. Observe dual pressure gauge to
system. determine which section is out. system. determine which section is out.
Vehicle can be moved with Vehicle can be moved with
EXTREME care. EXTREME care.
2. Loss of complete air brake 2. Vehicle cannot be moved. Spring 2. Loss of complete air brake 2. Vehicle cannot be moved. Spring
system. brakes will automatically be set. system. brakes will automatically be set.
Look for a malfunction in the main Look for a malfunction in the main
air supply system. air supply system.
CONDITION LOW AIR PRESSURE WARNING CONDITION LOW AIR PRESSURE WARNING
RED LIGHT COMES ON WHILE RED LIGHT COMES ON WHILE
DRIVING VEHICLE. DRIVING VEHICLE.
1. Loss of one section of the dual 1. Observe dual pressure gauge to 1. Loss of one section of the dual 1. Observe dual pressure gauge to
system. establish which section is out. system. establish which section is out.
Vehicle can be operated with Vehicle can be operated with
EXTREME care to the nearest EXTREME care to the nearest
safe parking area. safe parking area.
2. Loss of complete air brake 2. Spring brakes will automatically 2. Loss of complete air brake 2. Spring brakes will automatically
system. apply. Vehicle cannot be moved. system. apply. Vehicle cannot be moved.
Look for a malfunction in the main Look for a malfunction in the main
air supply system. air supply system.
3. Governor leaking. 3. Check for leakage. Repair or 3. Governor leaking. 3. Check for leakage. Repair or
replace governor. replace governor.
4. Compressor discharge valves 4. Repair compressor. 4. Compressor discharge valves 4. Repair compressor.
leaking. leaking.
259 259
CONDITION AIR PRESSURE DROPS QUICKLY CONDITION AIR PRESSURE DROPS QUICKLY
WITH ENGINE STOPPED AND WITH ENGINE STOPPED AND
BRAKES FULLY APPLIED. BRAKES FULLY APPLIED.
1. Treadle valve leaking. 1. Perform leakage test and make 1. Treadle valve leaking. 1. Perform leakage test and make
necessary repairs. necessary repairs.
2. Brake chamber leakage. 2. Repair or replace brake chamber. 2. Brake chamber leakage. 2. Repair or replace brake chamber.
3. Hose, tubing or fittings leaking. 3. Check all plumbing and make 3. Hose, tubing or fittings leaking. 3. Check all plumbing and make
AIR PRESSURE DROPS QUICKLY AIR PRESSURE DROPS QUICKLY

WITH ENGINE STOPPED AND WITH ENGINE STOPPED AND
CONDITION BRAKES RELEASED. CONDITION BRAKES RELEASED.
1. Treadle valve leaking. 1. Perform leakage test and make 1. Treadle valve leaking. 1. Perform leakage test and make
2. Hoses, tubing or fittings leaking. 2. Check all plumbing and make 2. Hoses, tubing or fittings leaking. 2. Check all plumbing and make
3. Parking brake chamber leaking. 3. Replace diaphragm. 3. Parking brake chamber leaking. 3. Replace diaphragm.
CONDITION AIR PRESSURE WILL NOT RISE CONDITION AIR PRESSURE WILL NOT RISE
TO NORMAL TO NORMAL
1. Reservoir drain cock opened. 1. Check drain cock. Close if 1. Reservoir drain cock opened. 1. Check drain cock. Close if
opened. opened.
2. Excessive air leakage from 2. Perform air leakage test, and 2. Excessive air leakage from 2. Perform air leakage test, and
system components. make necessary repairs. system components. make necessary repairs.
3. Governor out of adjustment. 3. Check governor setting. Make 3. Governor out of adjustment. 3. Check governor setting. Make
adjustment, if necessary. adjustment, if necessary.
4. Defective air pressure gauge. 4. Replace air pressure gauge. 4. Defective air pressure gauge. 4. Replace air pressure gauge.
5. Faulty compressor. 5. Repair or replace. 5. Faulty compressor. 5. Repair or replace.
260 260
CONDITION AIR PRESSURE RISES TO CONDITION AIR PRESSURE RISES TO

NORMAL SLOWLY NORMAL SLOWLY
1. Engine speed too low. 1. Check speed and make 1. Engine speed too low. 1. Check speed and make
adjustment. adjustment.
2. Excessive air leakage from 2. Perform air leakage test and 2. Excessive air leakage from 2. Perform air leakage test and
system components. make necessary repairs. system components. make necessary repairs.
3. Faulty air compressor. 3. Repair or replace. 3. Faulty air compressor. 3. Repair or replace.
CONDITION AIR PRESSURE RISES ABOVE CONDITION AIR PRESSURE RISES ABOVE
NORMAL NORMAL
1. Defective air gauge. 1. Disconnect gauge and install 1. Defective air gauge. 1. Disconnect gauge and install
master gauge. Observe air master gauge. Observe air
pressure. pressure.
2. Governor out of adjustment. 2. Adjust or replace governor. 2. Governor out of adjustment. 2. Adjust or replace governor.
3. Restriction in line between 3. Check line for kinks or other 3. Restriction in line between 3. Check line for kinks or other
governor and compressor restrictions. Replace as required. governor and compressor restrictions. Replace as required.
unloading mechanism. unloading mechanism.
4. Air compressor unloading 4. Repair or replace as required. 4. Air compressor unloading 4. Repair or replace as required.
mechanism malfunction. mechanism malfunction.
CONDITION INSUFFICIENT BRAKES CONDITION INSUFFICIENT BRAKES

1. Low air pressure in the brake 1. Check system pressure. Make 1. Low air pressure in the brake 1. Check system pressure. Make
system, excessive leaks or necessary repairs. system, excessive leaks or necessary repairs.
delivery pressure below normal. delivery pressure below normal.
2. Brake adjustment, lubrication or 2. Check condition of brakes. Make 2. Brake adjustment, lubrication or 2. Check condition of brakes. Make
relining necessary. necessary repairs. relining necessary. necessary repairs.
3. Mechanical failure of brake wheel 3. Check brake wheel components. 3. Mechanical failure of brake wheel 3. Check brake wheel components.
component. Make necessary repairs. component. Make necessary repairs.
4. Restriction in brake air line. 4. Check brake piping for kinks or 4. Restriction in brake air line. 4. Check brake piping for kinks or
other restrictions. Repair as other restrictions. Repair as
required. required.
261 261
CONDITION BRAKES APPLY TOO SLOWLY CONDITION BRAKES APPLY TOO SLOWLY
1. Brake adjustment or lubrication 1. Check brakes and make 1. Brake adjustment or lubrication 1. Check brakes and make
necessary. necessary repairs. necessary. necessary repairs.
2. Check causes under “Air 2. Follow corrections as outlined for 2. Check causes under “Air 2. Follow corrections as outlined for
Pressure Drops Quickly with possible causes. Pressure Drops Quickly with possible causes.
Engine Stopped and Brakes Fully Engine Stopped and Brakes Fully
Applied.” Applied.”
3. Restriction in tubing or hoses. 3. Check brake piping for kinks or 3. Restriction in tubing or hoses. 3. Check brake piping for kinks or
other restrictions. other restrictions.
CONDITION BRAKES RELEASE TOO SLOWLY CONDITION BRAKES RELEASE TOO SLOWLY
1. Treadle valve not returning to full 1. Check for accumulated dirt, 1. Treadle valve not returning to full 1. Check for accumulated dirt,
released position. gravel, etc., around treadle valve released position. gravel, etc., around treadle valve
pedal (floor-mounted valves). pedal (floor-mounted valves).
Clean and lubricate treadle roller Clean and lubricate treadle roller
and hinge pin, or repair or replace and hinge pin, or repair or replace
treadle valve. treadle valve.
2. Brake adjustment or lubrication 2. Check brakes. Correct as 2. Brake adjustment or lubrication 2. Check brakes. Correct as
necessary. necessary. necessary. necessary.
3. Restrictions in tubing or hoses. 3. Check brake piping for kinks or 3. Restrictions in tubing or hoses. 3. Check brake piping for kinks or
required. required.
4. Exhaust port of brake valve, quick 4. Check valves for proper 4. Exhaust port of brake valve, quick 4. Check valves for proper
release valve or relay valve operation. Repair as necessary. release valve or relay valve operation. Repair as necessary.
clogged or restricted. clogged or restricted.
CONDITION BRAKES DO NOT RELEASE CONDITION BRAKES DO NOT RELEASE

1. Broken or weak return springs. 1. Replace faulty springs. 1. Broken or weak return springs. 1. Replace faulty springs.
2. Treadle valve not fully released. 2. Repair or replace valve. Clean 2. Treadle valve not fully released. 2. Repair or replace valve. Clean
under pedal and check for seized under pedal and check for seized
hinge pin. hinge pin.
3. Restrictions in tubing or hoses. 3. Check brake piping for kinks or 3. Restrictions in tubing or hoses. 3. Check brake piping for kinks or
necessary. Check that hand necessary. Check that hand
control is not partially applied. control is not partially applied.
4. Parking brake chamber leaking. 4. Repair or replace. 4. Parking brake chamber leaking. 4. Repair or replace.
262 262
CONDITION BRAKES GRAB CONDITION BRAKES GRAB

1. Grease or oil on brake lining. 1. Replace brake lining. 1. Grease or oil on brake lining. 1. Replace brake lining.
2. Brake drum out of round. 2. Check brake drum for 2. Brake drum out of round. 2. Check brake drum for
concentricity. If out of round, concentricity. If out of round,
machine within allowable machine within allowable
limitations. limitations.
3. Defective brake valve. 3. Repair or replace brake valve. 3. Defective brake valve. 3. Repair or replace brake valve.
4. Brake linkage binding. 4. Check brake linkage for freedom 4. Brake linkage binding. 4. Check brake linkage for freedom
of movement. of movement.
CONDITION UNEVEN BRAKES CONDITION UNEVEN BRAKES
1. Brake adjustment, lubrication or 1. Adjust, lubricate or reline brakes 1. Brake adjustment, lubrication or 1. Adjust, lubricate or reline brakes
relining needed. as necessary. relining needed. as necessary.
2. Grease or oil on brake linings. 2. Replace brake lining. 2. Grease or oil on brake linings. 2. Replace brake lining.
3. Brake shoe or chamber release 3. Replace springs. 3. Brake shoe or chamber release 3. Replace springs.
springs broken. springs broken.
4. Brake drum out of round. 4. Check brake drum concentricity. If 4. Brake drum out of round. 4. Check brake drum concentricity. If
out of round, machine within out of round, machine within
allowable limitations. allowable limitations.
5. Brake chamber diaphragm 5. Repair or replace brake chamber. 5. Brake chamber diaphragm 5. Repair or replace brake chamber.
leaking. leaking.
CONDITION BRAKES DO NOT APPLY CONDITION BRAKES DO NOT APPLY
1. Restricted or broken tubing or 1. Check system. Locate problem 1. Restricted or broken tubing or 1. Check system. Locate problem
hoses. area. Repair or replace parts. hoses. area. Repair or replace parts.
2. Faulty treadle valve. 2. Repair or replace. 2. Faulty treadle valve. 2. Repair or replace.
263 263
NOTES NOTES
264 264
SPECIFICATIONS AND CAPACITIES SPECIFICATIONS AND CAPACITIES
SPECIFICATIONS AND SPECIFICATIONS AND

CAPACITIES CAPACITIES
102 102
Figure 102 — Specifications and Capacities Figure 102 — Specifications and Capacities
Components used on certain contract-engineered Components used on certain contract-engineered

vehicles may require lubricants other than those vehicles may require lubricants other than those
specified in this manual. Refer to the operator’s specified in this manual. Refer to the operator’s
manual supplied with these vehicles for a listing of manual supplied with these vehicles for a listing of
specified lubricants. specified lubricants.
265 265
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . 267 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . 267

DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
ANTIFREEZE SPECIFICATIONS . . . . . . . . . . . . . . . . 284 ANTIFREEZE SPECIFICATIONS . . . . . . . . . . . . . . . . 284
COOLANT CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 286 COOLANT CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 286
LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . . . . 288 LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . . . . 288
MACK ENGINE LINE-UP . . . . . . . . . . . . . . . . . . . . . . . 300 MACK ENGINE LINE-UP . . . . . . . . . . . . . . . . . . . . . . . 300
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . 304 CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . 304
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . 311 MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . 311
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . 312 SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . 312
266 266
LUBRICANT SPECIFICATIONS LUBRICANT SPECIFICATIONS

Lubrication of vital engine parts and chassis components, such as oil- Lubrication of vital engine parts and chassis components, such as oil-
lubricated wheel bearings, can best be accomplished by using the lubricated wheel bearings, can best be accomplished by using the
highest quality, recommended type and SAE grade lubricants. highest quality, recommended type and SAE grade lubricants.
To obtain the proper performance level lubricants, show these To obtain the proper performance level lubricants, show these
specifications to your oil supplier. Purchase from a reputable distributor specifications to your oil supplier. Purchase from a reputable distributor
who will assume the responsibility of recommending the proper who will assume the responsibility of recommending the proper
lubricants for the vehicle. Service components in accordance with lubricants for the vehicle. Service components in accordance with
MACK recommendations. DO NOT mix brands or types of lubricants. MACK recommendations. DO NOT mix brands or types of lubricants.
Engine Oils for MACK Diesel Engines Engine Oils for MACK Diesel Engines
EO-O PREMIUM PLUS EO-O PREMIUM PLUS
EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use
in all 2007 emission compliant MACK MP7 and MP8 engines. Chassis in all 2007 emission compliant MACK MP7 and MP8 engines. Chassis
equipped with a 2007 emission compliant engine, which can be equipped with a 2007 emission compliant engine, which can be
identified by the presence of a Diesel Particulate Filter (DPF), also identified by the presence of a Diesel Particulate Filter (DPF), also
require the use of Ultra Low Sulfur Diesel (ULSD) fuel. EO-O Premium require the use of Ultra Low Sulfur Diesel (ULSD) fuel. EO-O Premium
Plus oils exceed the new API service category CJ-4., and have Plus oils exceed the new API service category CJ-4., and have
demonstrated high performance capabilities in laboratory and field demonstrated high performance capabilities in laboratory and field
tests. To satisfy the requirements of EO-O Premium Plus, an oil must tests. To satisfy the requirements of EO-O Premium Plus, an oil must
pass the MACK T-11 test which measures the ability of the oil to resist pass the MACK T-11 test which measures the ability of the oil to resist
soot-related oil thickening, and the MACK T-12 test which is a 300-hour soot-related oil thickening, and the MACK T-12 test which is a 300-hour
test that measures the resistance of the oil to oxidation at higher oil test that measures the resistance of the oil to oxidation at higher oil
temperatures and the ability of the oil to control abrasive wear. The temperatures and the ability of the oil to control abrasive wear. The
T-12 test also measures cylinder wear and bearing abrasive wear. T-12 test also measures cylinder wear and bearing abrasive wear.
EO-O Premium Plus specification oil must also exceed other industry EO-O Premium Plus specification oil must also exceed other industry
standard tests that determine general and soot-related wear and standard tests that determine general and soot-related wear and
resistance to oxidation at higher temperatures. resistance to oxidation at higher temperatures.
Use the SAE grade oil as indicated in the following table for seasonal Use the SAE grade oil as indicated in the following table for seasonal
temperature changes. temperature changes.
267 267
Oil Ambient Temperature Oil Ambient Temperature

Specification in Degrees °C (°F) SAE Viscosity Grade Specification in Degrees °C (°F) SAE Viscosity Grade
EO-N Above −18° (0°) 15W40 5W40** EO-N Above −18° (0°) 15W40 5W40**
Premium Plus Premium Plus
’03 Consistently −18° (0°) 10W40 5W40** ’03 Consistently −18° (0°) 10W40 5W40**
or below* or below*
* At extremely low temperatures, use an engine block heater to keep the * At extremely low temperatures, use an engine block heater to keep the
engine warm during extended shutdown or layovers. engine warm during extended shutdown or layovers.
** Synthetic Oil ** Synthetic Oil
Gear Oils Gear Oils

GO-J and GO-J PLUS specification oils are compounded gear oils GO-J and GO-J PLUS specification oils are compounded gear oils
(mineral or synthetic base) for use in all MACK components which (mineral or synthetic base) for use in all MACK components which
require gear oil as a lubricant. These two classes of oils have different require gear oil as a lubricant. These two classes of oils have different
drain intervals, with GO-J used for standard drain intervals and GO-J drain intervals, with GO-J used for standard drain intervals and GO-J
PLUS used for extended drain intervals. For an explanation of vehicle PLUS used for extended drain intervals. For an explanation of vehicle
usage and an outline of oil change interval mileage/time requirements, usage and an outline of oil change interval mileage/time requirements,
refer to “PREVENTIVE MAINTENANCE PROGRAM” on page 14. refer to “PREVENTIVE MAINTENANCE PROGRAM” on page 14.
GO-J and GO-J PLUS gear oils are mandatory for use GO-J and GO-J PLUS gear oils are mandatory for use
in all MACK components which require gear oil as a in all MACK components which require gear oil as a
lubricant. lubricant.
GENERAL REQUIREMENTS GENERAL REQUIREMENTS

Both GO-J and GO-J PLUS gear oils must be blended from well- Both GO-J and GO-J PLUS gear oils must be blended from well-
refined virgin base stock (or synthetic) and properly compounded with refined virgin base stock (or synthetic) and properly compounded with
load-carrying and lubricity additives. Water content must be less than load-carrying and lubricity additives. Water content must be less than
600 ppm (ASTM D-6304, Proc. C). To be approved as MACK 600 ppm (ASTM D-6304, Proc. C). To be approved as MACK
Specification GO-J or GO-J PLUS, these oils must meet SAE J 2360, Specification GO-J or GO-J PLUS, these oils must meet SAE J 2360,
must be stable and must not contain any abrasive or corrosive must be stable and must not contain any abrasive or corrosive
ingredients. ingredients.
268 268
GEAR OILS FOR MACK COMPONENTS GEAR OILS FOR MACK COMPONENTS
Recommended SAE Grade Recommended SAE Grade

GO-J and GO-J PLUS* GO-J and GO-J PLUS*
Geared Component Mineral Synthetic Geared Component Mineral Synthetic
Carriers 80W90, 80W140, 75W90, 75W140, Carriers 80W90, 80W140, 75W90, 75W140,
85W140 80W140 85W140 80W140
Flywheel PTO 80W90, 80W140, 75W90, 75W140, Flywheel PTO 80W90, 80W140, 75W90, 75W140,
85W140 80W140 85W140 80W140
Transfer Case 80W90, 80W140, 75W90, 75W14, Transfer Case 80W90, 80W140, 75W90, 75W14,
85W140 80W140 85W140 80W140
Oil-Lubricated Wheel 80W90, 80W140, 75W90, 75W140, Oil-Lubricated Wheel 80W90, 80W140, 75W90, 75W140,
Bearings 85W140 80W140 Bearings 85W140 80W140
* GO-J PLUS is required for MACK geared component extended service drain * GO-J PLUS is required for MACK geared component extended service drain
interval. interval.
GEAR OILS FOR MACK TRANSMISSIONS GEAR OILS FOR MACK TRANSMISSIONS
Recommended SAE Grade Recommended SAE Grade

Ambient GO-J and GO-J PLUS* Ambient GO-J and GO-J PLUS*
Temperature Temperature
Model C° (F°) Mineral Synthetic Model C° (F°) Mineral Synthetic
All MACK All Temperature 80W90, 75W90, All MACK All Temperature 80W90, 75W90,
Transmissions Operations 80W140, 75W140, Transmissions Operations 80W140, 75W140,
85W140 80W140 85W140 80W140
* GO-J PLUS or TO-A PLUS is required for MACK transmission extended * GO-J PLUS or TO-A PLUS is required for MACK transmission extended
service drain interval. service drain interval.
Maximum safe operating oil temperature for MACK Maximum safe operating oil temperature for MACK
transmissions is 121°C (250°F) for mineral-based oil, transmissions is 121°C (250°F) for mineral-based oil,
and 148°C (300°F) for synthetic-based oil. and 148°C (300°F) for synthetic-based oil.
269 269
Transmission Oil Transmission Oil

TO-A PLUS specification transmission oil is an SAE 40 or 50 grade oil TO-A PLUS specification transmission oil is an SAE 40 or 50 grade oil
intended for use in all MACK transmissions being used in the Extended intended for use in all MACK transmissions being used in the Extended
Drain Interval Program. For an explanation of vehicle usage and an Drain Interval Program. For an explanation of vehicle usage and an
explanation of oil change interval time/mileage requirements, refer to explanation of oil change interval time/mileage requirements, refer to
“PREVENTIVE MAINTENANCE PROGRAM” on page 14. TO-A PLUS “PREVENTIVE MAINTENANCE PROGRAM” on page 14. TO-A PLUS
is a transmission fluid only. is a transmission fluid only.
TO-A PLUS specification oil is intended for use as a TO-A PLUS specification oil is intended for use as a
transmission lubricant only. DO NOT use TO-A PLUS transmission lubricant only. DO NOT use TO-A PLUS
in transfer cases, carriers or any other component that in transfer cases, carriers or any other component that
specified GO-J or GO-J PLUS gear oil. specified GO-J or GO-J PLUS gear oil.
GENERAL REQUIREMENTS GENERAL REQUIREMENTS

This oil must be an SAE 40 or 50 transmission oil, must be stable, must This oil must be an SAE 40 or 50 transmission oil, must be stable, must
not contain any abrasive or corrosive ingredients and must be not contain any abrasive or corrosive ingredients and must be
approved as MACK Specification TO-A PLUS. Water content must be approved as MACK Specification TO-A PLUS. Water content must be
less than 600 ppm ASTM D-6304, Proc. C. less than 600 ppm ASTM D-6304, Proc. C.
TRANSMISSION FLUID FOR MACK TRANSMISSIONS TRANSMISSION FLUID FOR MACK TRANSMISSIONS
Ambient Ambient
Temperature C° Recommended SAE Grade TO-A Temperature C° Recommended SAE Grade TO-A
Model (F°) PLUS* Model (F°) PLUS*
All MACK All Temperature SAE 40 or 50 All MACK All Temperature SAE 40 or 50
Transmissions Operations Transmissions Operations
* TO-A PLUS or GO-J PLUS is required for MACK transmission extended * TO-A PLUS or GO-J PLUS is required for MACK transmission extended
service drain interval. service drain interval.
Greases Greases
Grease must be high quality, and free of water, acid or other contents Grease must be high quality, and free of water, acid or other contents
which are harmful to the unit. which are harmful to the unit.
270 270
MG-C (CHASSIS LUBE) MG-C (CHASSIS LUBE)

General Requirements General Requirements
This grease shall be composed of oils and such additives as are This grease shall be composed of oils and such additives as are
required to provide the specified properties. This shall be an “EP” required to provide the specified properties. This shall be an “EP”
grease, and the thickener must be lithium based. grease, and the thickener must be lithium based.
Specific Requirements Specific Requirements
NLGI Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NLGI Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth
Worked Penetration: Worked Penetration:
60 Strokes, mm/10, D217* . . . . . . . . . . . . . . . . . . . 265–295 60 Strokes, mm/10, D217* . . . . . . . . . . . . . . . . . . . 265–295
Dropping point °C (°F), Min., D566* or D2265* . . . 175°C (348°F) Dropping point °C (°F), Min., D566* or D2265* . . . 175°C (348°F)
Rust Protection, Rating, Max., D1743* . . . . . . . . . . Pass Rust Protection, Rating, Max., D1743* . . . . . . . . . . Pass
Water Washout, 80°C, % Max., D1264* . . . . . . . . . 10 Water Washout, 80°C, % Max., D1264* . . . . . . . . . 10
Oil Separation, Mass %, Max., D1742* . . . . . . . . . 10 Oil Separation, Mass %, Max., D1742* . . . . . . . . . 10
High Temperature Life, Hrs., Min., D3527* . . . . . . . 40 High Temperature Life, Hrs., Min., D3527* . . . . . . . 40
EP Performance: EP Performance:
Load Wear Index, Kgf, Min., D2596* . . . . . . . . . . . 30 Load Wear Index, Kgf, Min., D2596* . . . . . . . . . . . 30
Weld Point, Kgf, Min., D2596* . . . . . . . . . . . . . . . . 200 Weld Point, Kgf, Min., D2596* . . . . . . . . . . . . . . . . 200
Timken OK Load, Kg. (Lbs.), Min., D2509* . . . . . . 18 (40) Timken OK Load, Kg. (Lbs.), Min., D2509* . . . . . . 18 (40)
Four Ball Wear Scar, mm, Max., D2266* . . . . . . . . 0.6 Four Ball Wear Scar, mm, Max., D2266* . . . . . . . . 0.6
Water, Mass %, Max., D95* . . . . . . . . . . . . . . . . . . 0.20 Water, Mass %, Max., D95* . . . . . . . . . . . . . . . . . . 0.20
Elastomer Compatibility: Cr NBR-L Elastomer Compatibility: Cr NBR-L
Volume ∆ , %, D4289* . . . . . . . . . . . . . . . . . . . . 0 to 30/−5 to +30 Volume ∆ , %, D4289* . . . . . . . . . . . . . . . . . . . . 0 to 30/−5 to +30
Shore A Hardness ∆ , Pts. D4289* . . . . . . . . . . 0 to −10 /+2 to −15 Shore A Hardness ∆ , Pts. D4289* . . . . . . . . . . 0 to −10 /+2 to −15
271 271
BASE OIL PROPERTIES BASE OIL PROPERTIES
Viscosity, 40°C, cSt. Min., D445* . . . . . . . . . . . . . . . 145 Viscosity, 40°C, cSt. Min., D445* . . . . . . . . . . . . . . . 145
Pour Point, °C (°F), Max., D97* . . . . . . . . . . . . . . . . −15°C (5°F) Pour Point, °C (°F), Max., D97* . . . . . . . . . . . . . . . . −15°C (5°F)
Flash Point, °C (°F), Min., D92* . . . . . . . . . . . . . . . . 205°C (400°F) Flash Point, °C (°F), Min., D92* . . . . . . . . . . . . . . . . 205°C (400°F)
Viscosity Index, Min., D2270* . . . . . . . . . . . . . . . . . 70 Viscosity Index, Min., D2270* . . . . . . . . . . . . . . . . . 70
MOLYBDENUM DISULFIDE (WHEN PRESENT) MOLYBDENUM DISULFIDE (WHEN PRESENT)
Concentration, %, Min., X-ray Fluorescent Concentration, %, Min., X-ray Fluorescent

Spectrograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Spectrograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Particle Size, Microns, Max., Fisher Subseive . . . . . 2.0 Particle Size, Microns, Max., Fisher Subseive . . . . . 2.0
There is a trend toward the use of multi-purpose grease. Some of the There is a trend toward the use of multi-purpose grease. Some of the
ingredients used in multi-purpose greases are considered fillers or ingredients used in multi-purpose greases are considered fillers or
abrasives by the roller bearing manufacturers. The use of these abrasives by the roller bearing manufacturers. The use of these
multi-purpose greases may void warranties. multi-purpose greases may void warranties.
272 272
ANDEROL 776 (EXTREME PRESSURE GREASE) ANDEROL 776 (EXTREME PRESSURE GREASE)
This grease is a tacky, synthetic diester-based grease containing This grease is a tacky, synthetic diester-based grease containing
molybdenum disulfide, and is formulated to have excellent load molybdenum disulfide, and is formulated to have excellent load
carrying ability and low friction. carrying ability and low friction.
Optimum Operating Range, °C (°F) . . . . . . . . . . . . −40° to 149° Optimum Operating Range, °C (°F) . . . . . . . . . . . . −40° to 149°
(−40° to 300°) (−40° to 300°)
NLGI Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NLGI Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Worked Penetration, D217* . . . . . . . . . . . . . . . . . . 310 Worked Penetration, D217* . . . . . . . . . . . . . . . . . . 310
Worked Stability, 100,000 strokes, D217*. . . . . . . . 350 Worked Stability, 100,000 strokes, D217*. . . . . . . . 350
Dropping Point °C (°F), D566* . . . . . . . . . . . . . . . . 185° (365°) Dropping Point °C (°F), D566* . . . . . . . . . . . . . . . . 185° (365°)
Oil Separation, 30 hours @ 100°C (212°F), % Oil Separation, 30 hours @ 100°C (212°F), %
FTMS 791, No. 321.2. . . . . . . . . . . . . . . . . . . . . 1 FTMS 791, No. 321.2. . . . . . . . . . . . . . . . . . . . . 1
Evaporation, 22 hours @ 99°C (210°F), Evaporation, 22 hours @ 99°C (210°F),

% D972*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 % D972*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Humidity Cabinet, hours, min., ASTM D1748 . . . . . 100 Humidity Cabinet, hours, min., ASTM D1748 . . . . . 100
Four Ball Wear, 1200 rpm, 75°C (167°F), 40 KG, Four Ball Wear, 1200 rpm, 75°C (167°F), 40 KG,
hr., mm., D2266* . . . . . . . . . . . . . . . . . . . . . . . . 0.4 hr., mm., D2266* . . . . . . . . . . . . . . . . . . . . . . . . 0.4
Four Ball EP, Weld-Point, KG, ASTM D2783 . . . . . 180 Four Ball EP, Weld-Point, KG, ASTM D2783 . . . . . 180
* ASTM test procedure. * ASTM test procedure.
BG-A (CLUTCH RELEASE BEARING GREASE) BG-A (CLUTCH RELEASE BEARING GREASE)
High temperature grease made for ball and roller bearings. This grease High temperature grease made for ball and roller bearings. This grease
must be NLGI grade 1 or 2, have a minimum melting point of 178°C must be NLGI grade 1 or 2, have a minimum melting point of 178°C
(350°F), and be stable and non-fibrous. (350°F), and be stable and non-fibrous.
273 273
RG-A (BRAKE) RG-A (BRAKE)

An extreme pressure lubricant which has high resistance to corrosion An extreme pressure lubricant which has high resistance to corrosion
and water leakage, superior adhesive-cohesive properties and low cold and water leakage, superior adhesive-cohesive properties and low cold
shear at sub-zero temperatures. For use in ArvinMeritor™-Standard shear at sub-zero temperatures. For use in ArvinMeritor™-Standard
Stopmaster brakes, it must comply with specification 1779-W-283. Stopmaster brakes, it must comply with specification 1779-W-283.
Shell Darina No. 1, Sun Sunnaplex No. 1 and Texaco Thermatex EP-1 Shell Darina No. 1, Sun Sunnaplex No. 1 and Texaco Thermatex EP-1
are approved equivalents. are approved equivalents.
WG-A (WHEEL BEARING GREASE) WG-A (WHEEL BEARING GREASE)

WG-A grease must be composed of only soaps and oils, and must be WG-A grease must be composed of only soaps and oils, and must be
free of fillers and abrasives. This grease must be non-corrosive to free of fillers and abrasives. This grease must be non-corrosive to
bearing parts in service or storage, and it will show no oil separation in bearing parts in service or storage, and it will show no oil separation in
service or storage. Also, WG-A must be a smooth, texture-type grease service or storage. Also, WG-A must be a smooth, texture-type grease
and have a dropping point in excess of 121°C (250°F) when tested in and have a dropping point in excess of 121°C (250°F) when tested in
accordance with ASTM method D217–52T. accordance with ASTM method D217–52T.
Moisture content should not be greater than 0.5%. The oil should have Moisture content should not be greater than 0.5%. The oil should have
a viscosity of 75 to 100 seconds at 99°C (210°F), near −31°C (0°F) a viscosity of 75 to 100 seconds at 99°C (210°F), near −31°C (0°F)
cold test, and it should be a refined product. For normal applications, cold test, and it should be a refined product. For normal applications,
this grease should have an ASTM penetration at 25°C (77°F) (ASTM this grease should have an ASTM penetration at 25°C (77°F) (ASTM
method D217–52T) not heavier than 265 when applied to the bearings. method D217–52T) not heavier than 265 when applied to the bearings.
WG-A grease shall not work softer than 310 penetration with WG-A grease shall not work softer than 310 penetration with
60 strokes in the grease worker or in service. With 5000 strokes in the 60 strokes in the grease worker or in service. With 5000 strokes in the
grease worker, WG-A shall not be softer than 340 penetration. The grease worker, WG-A shall not be softer than 340 penetration. The
worked grease (5000 strokes) shall not thicken to an ASTM penetration worked grease (5000 strokes) shall not thicken to an ASTM penetration
heavier than 250 when heated to 105°C (220°F) for a test period of heavier than 250 when heated to 105°C (220°F) for a test period of
16 hours, and shall not show excessive oil separation after this test. 16 hours, and shall not show excessive oil separation after this test.
274 274
SEMI-FLUID GREASE (WHEEL BEARING LUBRICANT) SEMI-FLUID GREASE (WHEEL BEARING LUBRICANT)
 
Semi-fluid grease, such as Mobilith SHC 007, is a high- Semi-fluid grease, such as Mobilith SHC 007, is a high-
performance, extreme-pressure grease which combines a synthetic- performance, extreme-pressure grease which combines a synthetic-
base fluid with a lithium complex soap thickener. The thickener system base fluid with a lithium complex soap thickener. The thickener system
provides structural stability, a high dropping point and excellent provides structural stability, a high dropping point and excellent
resistance to water wash. resistance to water wash.
NLGI Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 NLGI Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00

Soap Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lithium Complex Soap Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lithium Complex
Structure, Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth: Tacky Structure, Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth: Tacky
Color, Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Color, Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Worked Penetration: Worked Penetration:
앫 60 strokes, ASTM D217 . . . . . . . . . . . . . . . . 415 앫 60 strokes, ASTM D217 . . . . . . . . . . . . . . . . 415
앫 10,000 strokes, ASTM D217 . . . . . . . . . . . . . 420 앫 10,000 strokes, ASTM D217 . . . . . . . . . . . . . 420
앫 100,000 strokes, ASTM D217 . . . . . . . . . . . . 420 앫 100,000 strokes, ASTM D217 . . . . . . . . . . . . 420
Viscosity of Oil, ASTM D445 Viscosity of Oil, ASTM D445
앫 cSt @ 40°C . . . . . . . . . . . . . . . . . . . . . . . . . . 460 앫 cSt @ 40°C . . . . . . . . . . . . . . . . . . . . . . . . . . 460
앫 cSt @ 100°C . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 앫 cSt @ 100°C . . . . . . . . . . . . . . . . . . . . . . . . . 46.5
앫 SUS @ 100°F . . . . . . . . . . . . . . . . . . . . . . . . 2400 앫 SUS @ 100°F . . . . . . . . . . . . . . . . . . . . . . . . 2400
앫 SUS @ 210°F . . . . . . . . . . . . . . . . . . . . . . . . 215 앫 SUS @ 210°F . . . . . . . . . . . . . . . . . . . . . . . . 215
ISO VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 ISO VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
EP and Wear Protection EP and Wear Protection
앫 Four-Ball Wear Test, ASTM D2266 . . . . . . . . Scar diameter, 앫 Four-Ball Wear Test, ASTM D2266 . . . . . . . . Scar diameter,
0.70 mm max. 0.70 mm max.
앫 Four-Ball EP Weld Load, ASTM D2596 . . . . 250 kg 앫 Four-Ball EP Weld Load, ASTM D2596 . . . . 250 kg
앫 Load Wear Index . . . . . . . . . . . . . . . . . . . . . . 45 앫 Load Wear Index . . . . . . . . . . . . . . . . . . . . . . 45
Corrosion Prevention, ASTM D1743, rust test Corrosion Prevention, ASTM D1743, rust test
Pass Emcor/SKF Water Wash Test, IP 220 Pass Emcor/SKF Water Wash Test, IP 220
(modified) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 (modified) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0
US Steel Mobility, g/min. 18°C (64.4°F) . . . . . . . . . 27 US Steel Mobility, g/min. 18°C (64.4°F) . . . . . . . . . 27
Bomb Oxidation, ASTM D942, psi loss, Bomb Oxidation, ASTM D942, psi loss,
앫 100 hour 210°F . . . . . . . . . . . . . . . . . . . . . . . 2 앫 100 hour 210°F . . . . . . . . . . . . . . . . . . . . . . . 2
앫 500 hour 210°F . . . . . . . . . . . . . . . . . . . . . . . 4 앫 500 hour 210°F . . . . . . . . . . . . . . . . . . . . . . . 4
275 275
Fluids Fluids
Fluids must be high quality and free from water, acid or other contents Fluids must be high quality and free from water, acid or other contents
which are harmful to the unit. which are harmful to the unit.
BF-B (BRAKE FLUID) BF-B (BRAKE FLUID)
Use heavy-duty-type hydraulic brake fluid meeting the specifications of Use heavy-duty-type hydraulic brake fluid meeting the specifications of
FMVSS116, type DOT 3, 4 or 5. FMVSS116, type DOT 3, 4 or 5.
CF-A (CAB TILT) CF-A (CAB TILT)
Use fluid meeting military specification MIL-H-5606E. Use fluid meeting military specification MIL-H-5606E.
Power Steering Fluid Power Steering Fluid


Use DEXRON -type automatic transmission fluid in the power steering Use DEXRON-type automatic transmission fluid in the power steering
system as specified by the label located on the power steering system as specified by the label located on the power steering
reservoir. reservoir.
DEXRON-type automatic transmission fluid was DEXRON-type automatic transmission fluid was
implemented into production in the power steering implemented into production in the power steering
system on certain model chassis during December system on certain model chassis during December
2005, whereas certain other models use engine oil. 2005, whereas certain other models use engine oil.
Always refer to the label located on the power steering Always refer to the label located on the power steering
reservoir when adding fluid to the power steering reservoir when adding fluid to the power steering
system to ensure the proper fluid is used. system to ensure the proper fluid is used.
276 276
DIESEL FUEL DIESEL FUEL

DF-A (Ultra Low Sulfur Diesel Fuel Grades #1D and #2D) DF-A (Ultra Low Sulfur Diesel Fuel Grades #1D and #2D)
The proper selection of fuel is essential for good economy, The proper selection of fuel is essential for good economy,
performance and engine life. No. 2D ULSD should be used when performance and engine life. No. 2D ULSD should be used when
climatic conditions permit. No. 1D ULSD can be used during cold climatic conditions permit. No. 1D ULSD can be used during cold
weather conditions. Blends of No. 1D and No. 2D ULSD fuels can be weather conditions. Blends of No. 1D and No. 2D ULSD fuels can be
used to suit various climatic conditions. The chart below contains used to suit various climatic conditions. The chart below contains
mixing proportions for No. 1D and No. 2D ULSD fuels. mixing proportions for No. 1D and No. 2D ULSD fuels.
Recommended Fuel Mixing Proportions Recommended Fuel Mixing Proportions
Ambient Air Temperature No. 2 ULSD Fuel No. 1 ULSD Fuel Ambient Air Temperature No. 2 ULSD Fuel No. 1 ULSD Fuel
Above 0°C (32°F) 100% 0% Above 0°C (32°F) 100% 0%
0°C to −10°C (32°F to 14°F) 90% 10% 0°C to −10°C (32°F to 14°F) 90% 10%
−10°C to −20°C (14°F to −4°F) 70% 30% −10°C to −20°C (14°F to −4°F) 70% 30%
Below −20°C (−4°F) 50% 50% Below −20°C (−4°F) 50% 50%
Diesel engines for 2007 and later model year vehicles Diesel engines for 2007 and later model year vehicles
are designed to operate only with Ultra Low Sulfur are designed to operate only with Ultra Low Sulfur
Diesel (ULSD) fuel. Use of fuel other than ULSD will Diesel (ULSD) fuel. Use of fuel other than ULSD will
reduce the efficiency and durability of the engine, reduce the efficiency and durability of the engine,
permanently damage the advanced emission control permanently damage the advanced emission control
systems, reduce fuel economy and possibly prevent systems, reduce fuel economy and possibly prevent
the engine from running at all. Manufacturer’s the engine from running at all. Manufacturer’s
warranties are likely to be rendered void by usage of warranties are likely to be rendered void by usage of
improper or incorrect fuel, and usage of fuels other improper or incorrect fuel, and usage of fuels other
than ULSD fuel in diesel-powered vehicles is illegal than ULSD fuel in diesel-powered vehicles is illegal
and punishable with civil penalties. Use of fuel and punishable with civil penalties. Use of fuel
additives to compensate for the lower sulfur content is additives to compensate for the lower sulfur content is
NOT recommended by Mack Trucks. NOT recommended by Mack Trucks.
Always used good quality fuel meeting the specifications given in the Always used good quality fuel meeting the specifications given in the
following table. following table.
277 277
Requirements Requirements
ASTM ASTM
Property #2 ULSD #1 ULSD Method Property #2 ULSD #1 ULSD Method
Viscosity, cSt @ 40°C (104°F) 2.2–3.0 1.3–2.4 D445 Viscosity, cSt @ 40°C (104°F) 2.2–3.0 1.3–2.4 D445
API Gravity @ 15°C (60°F) 32–38 38–42 D287 API Gravity @ 15°C (60°F) 32–38 38–42 D287
Volatility, °C (°F) Volatility, °C (°F)
IBP, Min. 160 (320) 160 (320) D86 IBP, Min. 160 (320) 160 (320) D86
50% 246 to 288 221 to 238 50% 246 to 288 221 to 238
(475 to 550) (430 to 460) (475 to 550) (430 to 460)
90%, Max. 338 (640) 260 to 288 90%, Max. 338 (640) 260 to 288
(500 to 550) (500 to 550)
Cetane Number, Min. 43 43 D613 Cetane Number, Min. 43 43 D613
Lubricity, (mm) Max 520 520 D6079-02 Lubricity, (mm) Max 520 520 D6079-02
Reflectance, % 80 80 D6468 Reflectance, % 80 80 D6468
Total Sulfur, % Max. 0.0015 0.0015 D4294 Total Sulfur, % Max. 0.0015 0.0015 D4294
Pour Point, °C (°F) −23 (−10) −29 (−20) D97 Pour Point, °C (°F) −23 (−10) −29 (−20) D97
during winter Max. during winter Max.
months months
Corrosion — Copper Strip @ No. 3B ASTM 1-Max. D130 Corrosion — Copper Strip @ No. 3B ASTM 1-Max. D130
100°C (212°F) 100°C (212°F)
Conradson Carbon on 10% 0.35 0.25 D4530 Conradson Carbon on 10% 0.35 0.25 D4530
Residium, Max. Residium, Max.
Ash Content, % Max. 0.01 0.01 D482 Ash Content, % Max. 0.01 0.01 D482
Water and Sediment, % Max. 0.05 0.05 D1796 Water and Sediment, % Max. 0.05 0.05 D1796
Flash Point, °C (°F) 52 (125) 52 (125) D93 Flash Point, °C (°F) 52 (125) 52 (125) D93
Rust Prevention Light Rusting Light Rusting D665A Rust Prevention Light Rusting Light Rusting D665A
Max. Max. Max. Max.
The products furnished under this specification may be either cracked The products furnished under this specification may be either cracked
residuals or straight-run distillates, provided they come within the residuals or straight-run distillates, provided they come within the
scope of the specifications listed in the table above. Straight-run scope of the specifications listed in the table above. Straight-run
distillates, however, are preferred to recycled or cracked fuels. distillates, however, are preferred to recycled or cracked fuels.
278 278
For premium diesel fuel, use the Engine For premium diesel fuel, use the Engine
Manufacturer’s Association recommended Manufacturer’s Association recommended
specification FQP1B. specification FQP1B.
BioDiesel BioDiesel
Soy Methyl Ester (SME or SOME) BioDiesel fuel in blends up to a B5 Soy Methyl Ester (SME or SOME) BioDiesel fuel in blends up to a B5
concentration (5% blend) is approved by Mack Trucks, Inc. concentration (5% blend) is approved by Mack Trucks, Inc.
Although higher concentrations are available, Although higher concentrations are available,
concentrations up to B5 (maximum) are the only concentrations up to B5 (maximum) are the only
blends currently approved by Mack Trucks, Inc. blends currently approved by Mack Trucks, Inc.
MACK Engines are certified to comply with U.S. EPA MACK Engines are certified to comply with U.S. EPA
and California Air Resources Board (CARB) emissions and California Air Resources Board (CARB) emissions
standards based on the use of reference test fuels standards based on the use of reference test fuels
commonly available in the United States and specified commonly available in the United States and specified
in this manual. Use of alternative fuels, including in this manual. Use of alternative fuels, including
BioDiesel, may affect engine emissions. Mack Trucks, BioDiesel, may affect engine emissions. Mack Trucks,
Inc. does not warrant, and is not responsible for Inc. does not warrant, and is not responsible for
ensuring that the engines will comply with U.S. EPA ensuring that the engines will comply with U.S. EPA
and CARB emissions standards. and CARB emissions standards.
279 279
Handling and Storing Diesel Fuel Handling and Storing Diesel Fuel
Correct handling and storage of diesel fuel during cold and/or Correct handling and storage of diesel fuel during cold and/or
inclement winter weather is a key to satisfactory truck performance and inclement winter weather is a key to satisfactory truck performance and
reliability. reliability.
Observe the following hints and suggestions: Observe the following hints and suggestions:
앫 Storage tanks for diesel fuel should permit periodic removal of 앫 Storage tanks for diesel fuel should permit periodic removal of
sludge and water accumulations. This should be performed on a sludge and water accumulations. This should be performed on a
regular basis at approximately 10-day intervals. regular basis at approximately 10-day intervals.
앫 Fuel should be stored only in clean, non-contaminated tanks 앫 Fuel should be stored only in clean, non-contaminated tanks
situated in a cool, dry location. situated in a cool, dry location.
Never store diesel fuel in a galvanized container. The Never store diesel fuel in a galvanized container. The
fuel will dissolve the zinc in the galvanized coating. fuel will dissolve the zinc in the galvanized coating.
This zinc will remain in solution in the fuel until it is run This zinc will remain in solution in the fuel until it is run
through the engine where it will be deposited in the through the engine where it will be deposited in the
unit injectors causing serious damage. unit injectors causing serious damage.
앫 When parking the vehicle overnight or longer, fill the fuel tank(s) 앫 When parking the vehicle overnight or longer, fill the fuel tank(s)
to prevent build-up of condensation inside the tank(s). to prevent build-up of condensation inside the tank(s).
앫 Remove accumulations of snow, ice, oil or other debris from the 앫 Remove accumulations of snow, ice, oil or other debris from the
area of the filler cap before removing the cap from the tank. Also, area of the filler cap before removing the cap from the tank. Also,
remove snow-ice accumulations at the fuel tank vent. remove snow-ice accumulations at the fuel tank vent.
Diesel Fuel and Winter Operation Diesel Fuel and Winter Operation
For winter operation, certain fuel properties become more critical. For winter operation, certain fuel properties become more critical.
These properties include: These properties include:
앫 Cetane Number — A measure of the ignition value, or the time 앫 Cetane Number — A measure of the ignition value, or the time
required to heat, vaporize and ignite the fuel. The higher this required to heat, vaporize and ignite the fuel. The higher this
rating number, the faster the fuel will burn. rating number, the faster the fuel will burn.
앫 Pour Point — A temperature-related point at which fuel will no 앫 Pour Point — A temperature-related point at which fuel will no
longer flow through the fuel lines and cannot be pumped. longer flow through the fuel lines and cannot be pumped.
280 280
앫 Cloud Point — A temperature-related point at which fuel may 앫 Cloud Point — A temperature-related point at which fuel may
continue to flow through the fuel lines but filter restriction continue to flow through the fuel lines but filter restriction
(plugging) can occur due to crystallizing of the heavier parafinic (plugging) can occur due to crystallizing of the heavier parafinic
components of the fuel (also referred to as jelling or waxing in the components of the fuel (also referred to as jelling or waxing in the
fuel). fuel).
앫 Impurities — Water and sediment are of particular importance. 앫 Impurities — Water and sediment are of particular importance.
Water contamination can cause fuel line freeze-up, unit injector Water contamination can cause fuel line freeze-up, unit injector
and nozzle damage, as well as component corrosion. and nozzle damage, as well as component corrosion.
When operating in cold weather, fuel waxing can When operating in cold weather, fuel waxing can
cause many engine performance problems. Be sure to cause many engine performance problems. Be sure to
check for fuel jelling or waxing before proceeding with check for fuel jelling or waxing before proceeding with
any engine troubleshooting procedures. any engine troubleshooting procedures.
Diesel Fuel Additives Diesel Fuel Additives

Due to potential damage to the fuel system or engine, the use of Due to potential damage to the fuel system or engine, the use of
supplemental diesel fuel additives other than those added by the fuel supplemental diesel fuel additives other than those added by the fuel
manufacturer is not recommended by Mack Trucks, Inc. manufacturer is not recommended by Mack Trucks, Inc.
Adding isopropyl alcohol to reduce water Adding isopropyl alcohol to reduce water
contamination and freezing is NOT recommended. contamination and freezing is NOT recommended.
Never blend gasoline with diesel fuel. This practice Never blend gasoline with diesel fuel. This practice
can cause an explosive mixture resulting in can cause an explosive mixture resulting in
component destruction and engine/fuel system component destruction and engine/fuel system
damage. damage.
281 281
CETANE IMPROVERS CETANE IMPROVERS

Mack Trucks, Inc. currently approves the use of cetane improvers and Mack Trucks, Inc. currently approves the use of cetane improvers and
certain pour-point depressants to improve the combustibility and flow certain pour-point depressants to improve the combustibility and flow
characteristics of the fuel only if these additives are contained in the characteristics of the fuel only if these additives are contained in the
fuel as delivered and not added by the consumer. fuel as delivered and not added by the consumer.
앫 Be aware that the minimum cetane rating is now 앫 Be aware that the minimum cetane rating is now
43 instead of 40, but higher ratings may still be 43 instead of 40, but higher ratings may still be
necessary for operation in high altitudes or necessary for operation in high altitudes or
extreme cold weather. extreme cold weather.
앫 Also note that some industry experts state that 앫 Also note that some industry experts state that
cetane improvers may cause fuel system gum-up cetane improvers may cause fuel system gum-up
problems. problems.
Cetane improvers have the following benefits: Cetane improvers have the following benefits:
앫 Easier cold weather starting 앫 Easier cold weather starting
앫 Smoother engine operation 앫 Smoother engine operation
앫 Reduced diesel knock 앫 Reduced diesel knock
앫 Faster engine warm-up 앫 Faster engine warm-up
앫 Lower emissions 앫 Lower emissions
앫 Reduced misfire and white smoke cleanup time 앫 Reduced misfire and white smoke cleanup time
Fuel Warmers Fuel Warmers

The use of thermostatically controlled fuel warmers which will maintain The use of thermostatically controlled fuel warmers which will maintain
fuel temperatures above the gel point and below the flash point of the fuel temperatures above the gel point and below the flash point of the
fuel. fuel.
The only fuel warmers approved for use on MACK The only fuel warmers approved for use on MACK
engines are those which use the coolant to regulate engines are those which use the coolant to regulate
the temperature of the fuel. Exhaust gas fuel warmers the temperature of the fuel. Exhaust gas fuel warmers
are not satisfactory, nor are they approved for use. are not satisfactory, nor are they approved for use.
282 282
Engine Block Heater Engine Block Heater

The combination of a fuel warmer, one which uses the engine coolant The combination of a fuel warmer, one which uses the engine coolant
as the heating medium, and a block heater will alleviate winter starting as the heating medium, and a block heater will alleviate winter starting
and operating problems associated with fuel waxing. and operating problems associated with fuel waxing.
103 103

Figure 103 — Engine Block Heaters Figure 103 — Engine Block Heaters
283 283
ANTIFREEZE SPECIFICATIONS ANTIFREEZE SPECIFICATIONS

Ethylene glycol- or propylene glycol-based antifreezes are required in Ethylene glycol- or propylene glycol-based antifreezes are required in
MACK Class 8 trucks. All ethylene-glycol and propylene-glycol MACK Class 8 trucks. All ethylene-glycol and propylene-glycol
coolants must be low silicate antifreezes which meet ASTM D4985 test coolants must be low silicate antifreezes which meet ASTM D4985 test
and TMC RP329 criteria. These antifreezes are sometimes referred to and TMC RP329 criteria. These antifreezes are sometimes referred to
as heavy-duty diesel coolants. Passenger car coolants do NOT meet as heavy-duty diesel coolants. Passenger car coolants do NOT meet
this specification. this specification.
Be sure to maintain the required level of antifreeze protection for Be sure to maintain the required level of antifreeze protection for
anticipated winter temperatures in your area of operation. Mack Trucks, anticipated winter temperatures in your area of operation. Mack Trucks,
Inc. recommends an antifreeze mix in the range between 40% to 60%, Inc. recommends an antifreeze mix in the range between 40% to 60%,
depending upon climatic conditions in which the vehicle will be depending upon climatic conditions in which the vehicle will be
operated. operated.
Do not exceed a 60% solution of ethylene glycol or Do not exceed a 60% solution of ethylene glycol or
propylene glycol to water. A higher percentage will not propylene glycol to water. A higher percentage will not
increase protection. Concentrations over 60% increase protection. Concentrations over 60%
adversely affect freeze protection and heat transfer adversely affect freeze protection and heat transfer
rates. rates.
284 284
Additional guidelines for maintaining correct antifreeze protection Additional guidelines for maintaining correct antifreeze protection
include the following: include the following:
앫 Do not use antifreeze containing anti-leak additives in trucks 앫 Do not use antifreeze containing anti-leak additives in trucks
equipped with coolant filters or conditioners. Also, do not use equipped with coolant filters or conditioners. Also, do not use
soluble oil type antifreeze in any MACK cooling system. soluble oil type antifreeze in any MACK cooling system.
앫 Always mix the water/antifreeze solution before adding it to the 앫 Always mix the water/antifreeze solution before adding it to the
cooling system. cooling system.
앫 After adding coolant, run the engine until a minimum normal 앫 After adding coolant, run the engine until a minimum normal
operating temperature is reached. Check the coolant level and operating temperature is reached. Check the coolant level and
add coolant as needed. add coolant as needed.
앫 Concentration of antifreeze in the cooling system must be 앫 Concentration of antifreeze in the cooling system must be
checked with a refractometer twice per year. checked with a refractometer twice per year.
앫 Change coolant at the recommended interval as outlined in 앫 Change coolant at the recommended interval as outlined in
“COOLING SYSTEM” on page 91. “COOLING SYSTEM” on page 91.
A proper coolant mixture contains MACK-approved antifreeze and A proper coolant mixture contains MACK-approved antifreeze and
quality water meeting the minimum acceptable specifications listed in quality water meeting the minimum acceptable specifications listed in
the following table: the following table:
Property Limit ASTM Test Method Property Limit ASTM Test Method
Chloride (Cl), gr/gal (ppm) 2.4 (40) max. D512b, D512d, D4327 Chloride (Cl), gr/gal (ppm) 2.4 (40) max. D512b, D512d, D4327
Sulfate (SO4), gr/gal (ppm) 5.9 (100) max. D516b, D516d, D4327 Sulfate (SO4), gr/gal (ppm) 5.9 (100) max. D516b, D516d, D4327
Total Hardness, gr/gal 10 (170) max. D1126b Total Hardness, gr/gal 10 (170) max. D1126b
(ppm) (ppm)
Total Solids, gr/gal (ppm) 20 (340) D1293 Total Solids, gr/gal (ppm) 20 (340) D1293
Water can be tested by any reputable testing laboratory. If water Water can be tested by any reputable testing laboratory. If water
meeting the above specifications is not available, use de-ionized or meeting the above specifications is not available, use de-ionized or
distilled water rather than ordinary tap water to minimize the adverse distilled water rather than ordinary tap water to minimize the adverse
effects of minerals in the water. effects of minerals in the water.
285 285
COOLANT CAPACITIES COOLANT CAPACITIES

Coolant System Capacities Coolant System Capacities
Capacities may vary due to hoses and size of radiator, Capacities may vary due to hoses and size of radiator,
as well as accessory cooling equipment. After running as well as accessory cooling equipment. After running
the engine until normal operating temperature is the engine until normal operating temperature is
reached, check the coolant level and add coolant as reached, check the coolant level and add coolant as
needed. needed.
Use the chart shown below in conjunction with the Ethylene-Glycol and Use the chart shown below in conjunction with the Ethylene-Glycol and
Propylene-Glycol Protection Charts in this section to determine the Propylene-Glycol Protection Charts in this section to determine the
amount of antifreeze needed to protect your vehicle. amount of antifreeze needed to protect your vehicle.
Coolant Capacity in Coolant Capacity in

Chassis Model Engine Model Liters (Quarts) Chassis Model Engine Model Liters (Quarts)
CXU MP7* 52 (55) CXU MP7* 52 (55)

MP8* 54 (57) MP8* 54 (57)
CHU MP7* 52 (55) CHU MP7* 52 (55)

MP8* 54 (57) MP8* 54 (57)
GU7 MP7* 52 (55) GU7 MP7* 52 (55)

MP8* 54 (57) MP8* 54 (57)
GU8 MP7* 52 (55) GU8 MP7* 52 (55)

MP8* 54 (57) MP8* 54 (57)
MRU MP7* 48 (51) MRU MP7* 48 (51)

MP8** 52 (55) MP8** 52 (55)
LEU MP7*** 58 (61) LEU MP7*** 58 (61)
* Coolant capacities listed are for chassis equipped with manual * Coolant capacities listed are for chassis equipped with manual
transmissions. For automatic transmissions, add 9.5 liters (10 qts.). transmissions. For automatic transmissions, add 9.5 liters (10 qts.).
** Allison automatic transmission is not an available option for MRU ** Allison automatic transmission is not an available option for MRU
models equipped with an MP8 engine. models equipped with an MP8 engine.
*** LEU models are not available with a manual transmission. *** LEU models are not available with a manual transmission.
286 286
Use the following antifreeze protection charts to determine the Use the following antifreeze protection charts to determine the
percentage of antifreeze needed to achieve specific protection levels percentage of antifreeze needed to achieve specific protection levels
for various coolant systems. for various coolant systems.
ETHYLENE-GLYCOL PROTECTION CHART ETHYLENE-GLYCOL PROTECTION CHART
Ethylene Glycol Ambient Air Temperature Ethylene Glycol Ambient Air Temperature
40% −24°C (−12°F) 40% −24°C (−12°F)
50% −37°C (−34°F) 50% −37°C (−34°F)
60% −52°C (−62°F) 60% −52°C (−62°F)
PROPYLENE-GLYCOL PROTECTION CHART PROPYLENE-GLYCOL PROTECTION CHART
Propylene Glycol Ambient Air Temperature Propylene Glycol Ambient Air Temperature
40% −21°C (−6°F) 40% −21°C (−6°F)
50% −33°C (−27°F) 50% −33°C (−27°F)
60% −49°C (−56°F) 60% −49°C (−56°F)
287 287
LUBRICANTS AND CAPACITIES LUBRICANTS AND CAPACITIES
Components used on certain contract-engineered Components used on certain contract-engineered

vehicles may require lubricants other than those vehicles may require lubricants other than those
specified in this manual. Refer to the operator’s specified in this manual. Refer to the operator’s
manual supplied with these vehicles for a listing of manual supplied with these vehicles for a listing of
specified lubricants. specified lubricants.
MACK Engines MACK Engines

(See table on page 268 for recommended SAE Grades) (See table on page 268 for recommended SAE Grades)
System Capacity* System Capacity*

Engine Lubricant Liters (Quarts) Engine Lubricant Liters (Quarts)
MACK MP7 EO-O Premium Plus 36 (38) MACK MP7 EO-O Premium Plus 36 (38)
MACK MP8 MACK MP8

Plastic Oil Pan 33 (34.9) Plastic Oil Pan 33 (34.9)
Steel Oil Pan Steel Oil Pan
(forward sump) 37 (39.1) (forward sump) 37 (39.1)
Steel Oil Pan Steel Oil Pan
(rear sump) 33 (34.9) (rear sump) 33 (34.9)
* Total system capacity (dry, after engine overhaul). * Total system capacity (dry, after engine overhaul).
288 288
Oil Change Capacity: Oil Change Capacity:

앫 MP7 Engines 앫 MP7 Engines
— 30 liters (31.7 quarts) in engine, 6 liters (6.3 quarts) to prefill — 30 liters (31.7 quarts) in engine, 6 liters (6.3 quarts) to prefill
oil filters oil filters
앫 MP8 Engines 앫 MP8 Engines
— Plastic Oil Pan (highway models only) — 27 liters — Plastic Oil Pan (highway models only) — 27 liters
(28.5 quarts) in engine, 6 liters (6.3 quarts) to prefill oil filters (28.5 quarts) in engine, 6 liters (6.3 quarts) to prefill oil filters
— Steel Oil Pan (axle back vocational vehicles with front — Steel Oil Pan (axle back vocational vehicles with front
sump) — 31 liters (32.8 quarts) in engine, 6 liters sump) — 31 liters (32.8 quarts) in engine, 6 liters
(6.3 quarts) to prefill oil filters (6.3 quarts) to prefill oil filters
— Steel Oil Pan (axle forward vocational vehicles with rear — Steel Oil Pan (axle forward vocational vehicles with rear
sump) — 27 liters (28.5 quarts) in engine, 6 liters sump) — 27 liters (28.5 quarts) in engine, 6 liters
(6.3 quarts) to prefill oil filters (6.3 quarts) to prefill oil filters
289 289
MACK MAXITORQUE ES T300 Series Transmissions MACK MAXITORQUE ES T300 Series Transmissions
(Refer to “GEAR OILS FOR MACK TRANSMISSIONS” on page 269 (Refer to “GEAR OILS FOR MACK TRANSMISSIONS” on page 269
for recommended SAE grades) for recommended SAE grades)
T300 Model Capacity* Liters T300 Model Capacity* Liters

Designation Lubricant (Pints) Designation Lubricant (Pints)
T306G GO-J, GO-J PLUS**, TO-A 9.5 (20) T306G GO-J, GO-J PLUS**, TO-A 9.5 (20)
PLUS** PLUS**
TM308 11.4 (24) TM308 11.4 (24)
TM308M 14.2 (30) TM308M 14.2 (30)
T309 11.4 (24) T309 11.4 (24)
T309LR 11.4 (24) T309LR 11.4 (24)
TM309 11.4 (24) TM309 11.4 (24)
TM309M 14.2 (30) TM309M 14.2 (30)
T310 11.4 (24) T310 11.4 (24)
T310M/MLR 14.2 (30) T310M/MLR 14.2 (30)
T310ME 14.2 (30) T310ME 14.2 (30)
T313LR 14.2 (30) T313LR 14.2 (30)
T313 14.2 (30) T313 14.2 (30)
T318LR 14.2 (30) T318LR 14.2 (30)
T318 14.2 (30) T318 14.2 (30)
T313LR21 14.2 (30) T313LR21 14.2 (30)
T318LR21 14.2 (30) T318LR21 14.2 (30)
* Exact amount depends on inclination of transmission. Also, if equipped with * Exact amount depends on inclination of transmission. Also, if equipped with
a transmission oil cooler or RMPTO, specified oil capacity may vary. Fill to a transmission oil cooler or RMPTO, specified oil capacity may vary. Fill to
level of filler opening. DO NOT overfill. level of filler opening. DO NOT overfill.
** GO-J PLUS and TO-A PLUS required for extended drain interval. TO-A ** GO-J PLUS and TO-A PLUS required for extended drain interval. TO-A
PLUS is a transmission lubricant only, and not to be used in other geared PLUS is a transmission lubricant only, and not to be used in other geared
290 290
Allison Transmissions* Allison Transmissions*
ALLISON TRANSMISSION LUBRICANTS AND CAPACITIES ALLISON TRANSMISSION LUBRICANTS AND CAPACITIES
Capacity — Liters Capacity — Liters
(Quarts) (Quarts)
Transmission* Lubricant Initial Fill** Refill*** Transmission* Lubricant Initial Fill** Refill***
4000/4500 MIL-PRF-46167 4000/4500 MIL-PRF-46167
RDS/EVS/HS Castrol TranSynd RDS/EVS/HS Castrol TranSynd
Deep oil sump with or Dexron VI 48 (51) 43 (45) Deep oil sump with or Dexron VI 48 (51) 43 (45)
PTO PTO
Shallow sump with 41 (43) 33 (34) Shallow sump with 41 (43) 33 (34)
PTO PTO
Deep oil sump 45 (48) 40 (42) Deep oil sump 45 (48) 40 (42)
without PTO without PTO
Shallow sump 38 (40) 30 (31) Shallow sump 38 (40) 30 (31)
without PTO without PTO
Grade Minimum Ambient Grade Minimum Ambient
(SAE) or oil Temperature °C (°F) (SAE) or oil Temperature °C (°F)
type type
MIL-PRF- –32 (–25) MIL-PRF- –32 (–25)
46167 –30 (–22) 46167 –30 (–22)
0W-20 0W-20
(Arctic oil) (Arctic oil)
TranSynd TranSynd
Dexron VI –25 (–13) Dexron VI –25 (–13)
10W –20 (–4) 10W –20 (–4)
15W-40 –15 (5) 15W-40 –15 (5)
30W 0 (32) 30W 0 (32)
40W 10 (50) 40W 10 (50)
Temperatures below those listed above require pre-heat. Temperatures below those listed above require pre-heat.
* All capacities are for the transmission alone and do not include external * All capacities are for the transmission alone and do not include external
piping such as for filters, coolers, etc. piping such as for filters, coolers, etc.
** Initial fill capacity is the amount of lubricant needed to fill a totally dry ** Initial fill capacity is the amount of lubricant needed to fill a totally dry
transmission such as after an overhaul. transmission such as after an overhaul.
*** Refill capacity is the amount of lubricant needed to fill a unit that has been *** Refill capacity is the amount of lubricant needed to fill a unit that has been
drained for the purpose of changing the transmission fluid. drained for the purpose of changing the transmission fluid.
For Allison transmission oil level check and change intervals, refer to For Allison transmission oil level check and change intervals, refer to
the Allison transmission service literature. the Allison transmission service literature.
291 291
Eaton Fuller Manual Transmissions Eaton Fuller Manual Transmissions
EATON FULLER MANUAL TRANSMISSIONS EATON FULLER MANUAL TRANSMISSIONS
Capacity Capacity
Transmission Lubricant** Liters (Pints)* Transmission Lubricant** Liters (Pints)*
9 Speeds Eaton-Approved Synthetic Transmission 9 Speeds Eaton-Approved Synthetic Transmission
RT-13609 Series Lubricant Specification PS-164 Rev 7*** 12.7 (27) RT-13609 Series Lubricant Specification PS-164 Rev 7*** 12.7 (27)
RT-14609 Series (refer to Note 2 on page 25) 12.7 (27) RT-14609 Series (refer to Note 2 on page 25) 12.7 (27)
RT-16709 Series 12.7 (27) RT-16709 Series 12.7 (27)
10 Speeds Grade Ambient Temp. 10 Speeds Grade Ambient Temp.
RT-14908LL Series (SAE) °C (°F) 13 (28) RT-14908LL Series (SAE) °C (°F) 13 (28)
RT-16908LL Series 50 All Temperatures 13 (28) RT-16908LL Series 50 All Temperatures 13 (28)
FR-13210 Series 11.1 (23.5) FR-13210 Series 11.1 (23.5)
FRO-18210C 11.1 (23.5) FRO-18210C 11.1 (23.5)
The following oil specifications are not The following oil specifications are not
approved for extended drain intervals or approved for extended drain intervals or
the Eaton extended warranty program. the Eaton extended warranty program.
Heavy-Duty Engine Oil Meeting Heavy-Duty Engine Oil Meeting
Specification MIL-L-2104 D Specification MIL-L-2104 D
or or
Caterpillar TO-4 Caterpillar TO-4
11 Speeds 11 Speeds
RTO-14909ALL 13 (28) RTO-14909ALL 13 (28)
RTO-16909ALL 13 (28) RTO-16909ALL 13 (28)
13 Speeds Grade Ambient Temp. 13 Speeds Grade Ambient Temp.
RT-14913 Series (SAE) °C (°F) 13 (28) RT-14913 Series (SAE) °C (°F) 13 (28)
RT-16913 Series 50 Above −12° (10°) 13 (28) RT-16913 Series 50 Above −12° (10°) 13 (28)
RTLO-18913A 40 Above −12° (10°) 13 (28) RTLO-18913A 40 Above −12° (10°) 13 (28)
30 Below −12° (10°) 30 Below −12° (10°)
15 Speeds 15 Speeds
RT-14915 Series 13 (28) RT-14915 Series 13 (28)
RT-16915 Series 13 (28) RT-16915 Series 13 (28)
18 Speeds Refer to lubricant specifications on 18 Speeds Refer to lubricant specifications on
RT-14918 Series previous page. 13 (28) RT-14918 Series previous page. 13 (28)
RTLO-16918B 13 (28) RTLO-16918B 13 (28)
RTLO-18918B 13 (28) RTLO-18918B 13 (28)
* Capacities listed are approximate. Exact amount depends upon degree of engine * Capacities listed are approximate. Exact amount depends upon degree of engine
and transmission inclination. Always fill transmission to level of filler plug hole. DO and transmission inclination. Always fill transmission to level of filler plug hole. DO
NOT overfill. Capacity of transmissions equipped with PTOs or oil coolers will be NOT overfill. Capacity of transmissions equipped with PTOs or oil coolers will be
greater than capacities listed. greater than capacities listed.
** Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX ** Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX
OILS IN THE TRANSMISSION. OILS IN THE TRANSMISSION.
*** Eaton-approved synthetic lubricants are required for extended drain intervals and *** Eaton-approved synthetic lubricants are required for extended drain intervals and
the Eaton extended warranty. Refer to Eaton Fuller service literature for the Eaton extended warranty. Refer to Eaton Fuller service literature for
recommended drain intervals and warranty information. recommended drain intervals and warranty information.
292 292
EATON FULLER AUTOSHIFT™ EATON FULLER AUTOSHIFT™
Capacity Capacity
Liters Liters
Model Lubricant* (Pints)** Model Lubricant* (Pints)**
Eaton-Approved Synthetic Transmission Eaton-Approved Synthetic Transmission

Lubricant Specification PS-164 Rev 7*** Lubricant Specification PS-164 Rev 7***
(refer to Note 2 on page 25) (refer to Note 2 on page 25)
Grade Ambient Temp. Grade Ambient Temp.

(SAE) °C (°F) (SAE) °C (°F)
10 Speed 12 (26) 10 Speed 12 (26)

RTO-14910(B)(C)-AS3 RTO-14910(B)(C)-AS3
50 All Temperatures 50 All Temperatures
RTO-16910(B)(C)-AS3 12 (26) RTO-16910(B)(C)-AS3 12 (26)
18 Speed The following oil specifications are not 13 (28) 18 Speed The following oil specifications are not 13 (28)
RTLO-14918(A)-AS3 approved for extended drain intervals or RTLO-14918(A)-AS3 approved for extended drain intervals or
the Eaton extended warranty. the Eaton extended warranty.
Heavy-Duty Engine Oil Heavy-Duty Engine Oil
RTLO-16918A-AS3 Meeting Specification 13 (28) RTLO-16918A-AS3 Meeting Specification 13 (28)
MIL-L-2104 D MIL-L-2104 D
or or

(SAE) °C (°F) (SAE) °C (°F)
50 Above −12° (10°) 50 Above −12° (10°)
40 Above −12° (10°) 40 Above −12° (10°)
30 Below −12° (10°) 30 Below −12° (10°)
* Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX * Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX
** Capacities listed are approximate. Exact amount depends upon degree of engine ** Capacities listed are approximate. Exact amount depends upon degree of engine
and transmission inclination. Always fill transmission to level of filter plug hole. DO and transmission inclination. Always fill transmission to level of filter plug hole. DO
293 293
EATON FULLER ULTRASHIFT™ EATON FULLER ULTRASHIFT™
Capacity Capacity
Transmission* Lubricant Liters (Pints) Transmission* Lubricant Liters (Pints)
RTO-14910B-DM3 Eaton-Approved Synthetic Transmission RTO-14910B-DM3 Eaton-Approved Synthetic Transmission

RTO-16910B-DM3 Lubricant Specification PS-164 Rev 7*** 12 (26) RTO-16910B-DM3 Lubricant Specification PS-164 Rev 7*** 12 (26)
(refer to Note 2 on page 25) 12 (26) (refer to Note 2 on page 25) 12 (26)

(SAE) °C (°F) (SAE) °C (°F)
50 All Temperatures 50 All Temperatures
The following oil specifications are not The following oil specifications are not
approved for extended drain intervals or approved for extended drain intervals or
the Eaton extended warranty. the Eaton extended warranty.
Heavy-Duty Engine Oil Meeting Heavy-Duty Engine Oil Meeting
Specification MIL-L-2104 D Specification MIL-L-2104 D
or or

(SAE) °C (°F) (SAE) °C (°F)
50 Above −12° (10°) 50 Above −12° (10°)
40 Above −12° (10°) 40 Above −12° (10°)
30 Below −12° (10°) 30 Below −12° (10°)
* Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX * Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX
** Capacities listed are approximate. Exact amount depends upon degree of engine ** Capacities listed are approximate. Exact amount depends upon degree of engine
and transmission inclination. Always fill transmission to level of filler plug hole. DO and transmission inclination. Always fill transmission to level of filler plug hole. DO
294 294
Steering System Steering System
STEERING SYSTEM LUBRICANTS AND CAPACITIES STEERING SYSTEM LUBRICANTS AND CAPACITIES
Steering System Lubricant Capacity Liters (Pints) Steering System Lubricant Capacity Liters (Pints)
Power Steering DEXRON-type 1.9 (4) Single Gear Power Steering DEXRON-type 1.9 (4) Single Gear
Reservoir Capacity automatic 3.8 (8) Dual Gear Reservoir Capacity automatic 3.8 (8) Dual Gear
transmission fluid transmission fluid
Beginning December 2005, Mack Trucks, Inc. began Beginning December 2005, Mack Trucks, Inc. began
phasing DEXRON III into production as the factory fill phasing DEXRON III into production as the factory fill
for the power steering system. Vehicles utilizing for the power steering system. Vehicles utilizing
DEXRON-type automatic transmission fluid in the DEXRON-type automatic transmission fluid in the
power steering system are identified by the label power steering system are identified by the label
affixed to the power steering reservoir. When adding affixed to the power steering reservoir. When adding
fluid to the power steering system, always check the fluid to the power steering system, always check the
label on the side of the reservoir and be sure to use label on the side of the reservoir and be sure to use
295 295
Rear Axles Rear Axles

(See “GEAR OILS FOR MACK COMPONENTS” on page 269 for (See “GEAR OILS FOR MACK COMPONENTS” on page 269 for
MACK recommended SAE grades) MACK recommended SAE grades)
REAR AXLE LUBRICANTS AND CAPACITIES REAR AXLE LUBRICANTS AND CAPACITIES
Capacity Capacity
Rear Axle Carrier Lubricant Liters (Pints) Rear Axle Carrier Lubricant Liters (Pints)
MACK MACK
RA23R CRD203 (1) GO-J/GO-J PLUS* 16.3 (34.5) RA23R CRD203 (1) GO-J/GO-J PLUS* 16.3 (34.5)
ArvinMeritor™ ArvinMeritor™
RS-23-161 R160 Series GL-5 or MIL-PRF-2105E 17.6 (37.2) RS-23-161 R160 Series GL-5 or MIL-PRF-2105E 17.6 (37.2)
GL-5 or MIL-PRF-2105E GL-5 or MIL-PRF-2105E
RS-23-186 R180 Series GL-5 or MIL-PRF-2105E 22.4 (47.3) RS-23-186 R180 Series GL-5 or MIL-PRF-2105E 22.4 (47.3)
Eaton/Dana Eaton/Dana
S23-190 S23-190 GL-5 or MIL-PRF-2105E 17.5 (37) S23-190 S23-190 GL-5 or MIL-PRF-2105E 17.5 (37)
* GO-J PLUS required for MACK geared component extended service drain interval. * GO-J PLUS required for MACK geared component extended service drain interval.
For service information, SAE grades and lubricant change intervals for For service information, SAE grades and lubricant change intervals for
axles other than those manufactured by Mack Trucks, Inc., refer to the axles other than those manufactured by Mack Trucks, Inc., refer to the
specific axle manufacturer’s service literature. specific axle manufacturer’s service literature.
296 296
Tandem Axles Tandem Axles

(See table on page 269 for MACK recommended SAE (See table on page 269 for MACK recommended SAE
grades) grades)
TANDEM AXLE LUBRICANTS AND CAPACITIES TANDEM AXLE LUBRICANTS AND CAPACITIES
Capacity** Liters Capacity** Liters

(Pints) (Pints)
Front- Rear- Front- Rear-

Rear Rear Rear Rear
Axle Model Carrier Lubricant Axle Axle Axle Model Carrier Lubricant Axle Axle
S(-)(-)34R CRDPC92 (1) GO-J/GO-J PLUS* 16.6 (35) 16.1 (34) S(-)(-)34R CRDPC92 (1) GO-J/GO-J PLUS* 16.6 (35) 16.1 (34)
CRD93(1) CRD93(1)
CRD(P)202(1)/ GO-J/GO-J PLUS* 17 (36) 16.3 CRD(P)202(1)/ GO-J/GO-J PLUS* 17 (36) 16.3
CRD 203(1) (34.5) CRD 203(1) (34.5)
S(-)(-)38R CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34) S(-)(-)38R CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34)
CRD93(1) CRD93(1)
CRDP202(1)/ GO-J/GO-J PLUS* 17 (36) 16.3 CRDP202(1)/ GO-J/GO-J PLUS* 17 (36) 16.3
CRD 203(1) (34.5) CRD 203(1) (34.5)
S(-)(-)40 CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34) S(-)(-)40 CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34)
CRD93(1) CRD93(1)
CRDPC202(1)/ GO-J/GO-J PLUS* 17 (36) 16.3 CRDPC202(1)/ GO-J/GO-J PLUS* 17 (36) 16.3
CRDPC203(1) (34.5) CRDPC203(1) (34.5)
S(-)(-)440 CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34) S(-)(-)440 CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34)
CRD93(1) CRD93(1)
CRD203(1) (34.5) CRD203(1) (34.5)
S(-)462 CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34) S(-)462 CRDPC92(1)/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34)
CRD93(1) CRD93(1)
CRD203(1) (34.5) CRD203(1) (34.5)
S(-)52 CRDPC112/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34) S(-)52 CRDPC112/ GO-J/GO-J PLUS* 16.6 (35) 16.1 (34)
CRD113 CRD113
CRD203(1) (34.5) CRD203(1) (34.5)
297 297

(Pints) (Pints)

Rear Rear Rear Rear
CRD113 CRD113
CRD202(1)/ GO-J/GO-J PLUS 17 (36) 16.3 CRD202(1)/ GO-J/GO-J PLUS 17 (36) 16.3
CRD203(1) (34.5) CRD203(1) (34.5)
CRD113 CRD113
CRD203(1) (34.5) CRD203(1) (34.5)
S(-)652 CRDP95/CRD96 GO-J/GO-J PLUS* 17.9 (38) 17 (36) S(-)652 CRDP95/CRD96 GO-J/GO-J PLUS* 17.9 (38) 17 (36)
Eaton/Dana Eaton/Dana
DS/ DS/RS405(P) GL-5 (mineral) 14.7 13.2 DS/ DS/RS405(P) GL-5 (mineral) 14.7 13.2
RS405(P) SHAES-256 (31)*** (28)*** RS405(P) SHAES-256 (31)*** (28)***
(synthetic) (synthetic)
DST40(P) DST40 GL-5 (mineral) 14.7 13.2 DST40(P) DST40 GL-5 (mineral) 14.7 13.2
SHAES-256 (31)*** (28)*** SHAES-256 (31)*** (28)***
DST41(P) DST41 GL-5 (mineral) 14.7 13.2 DST41(P) DST41 GL-5 (mineral) 14.7 13.2
SHAES-256 (31)*** (28)*** SHAES-256 (31)*** (28)***
D46-170HP D46-170 GL-5 (mineral) 18.5 18.5 D46-170HP D46-170 GL-5 (mineral) 18.5 18.5
SHAES-256 (39)*** (39)*** SHAES-256 (39)*** (39)***
298 298

(Pints) (Pints)

Rear Rear Rear Rear
ArvinMeritor ArvinMeritor
RT40- RT40-145 GL-5 14.3 12.2 RT40- RT40-145 GL-5 14.3 12.2
145(A) (30.2) (25.8) 145(A) (30.2) (25.8)
RT46-160 RT46-160 GL-5 18.5 16.3 RT46-160 RT46-160 GL-5 18.5 16.3
(39.1) (34.4) (39.1) (34.4)
RT46- RT46-164 GL-5 18.0 (38) 15.0 (33) RT46- RT46-164 GL-5 18.0 (38) 15.0 (33)
164EH/P 164EH/P
* GO-J PLUS required for MACK geared component extended service drain intervals. * GO-J PLUS required for MACK geared component extended service drain intervals.
** Proper oil level is best determined by checking oil level in reference to the oil filler ** Proper oil level is best determined by checking oil level in reference to the oil filler
plug hole. plug hole.
*** Carrier capacity assumes 0-degree installation angle. Installation angles exceeding *** Carrier capacity assumes 0-degree installation angle. Installation angles exceeding
10 degrees, or when vehicle must negotiate continuous or long grades, a standpipe 10 degrees, or when vehicle must negotiate continuous or long grades, a standpipe
may be required to raise oil level. Refer to Eaton Roadranger service literature for may be required to raise oil level. Refer to Eaton Roadranger service literature for
additional information. additional information.
For service information, SAE grades and lubricant change intervals for For service information, SAE grades and lubricant change intervals for
axles other than those manufactured by Mack Trucks, Inc., refer to the axles other than those manufactured by Mack Trucks, Inc., refer to the
specific axle manufacturer’s service literature. specific axle manufacturer’s service literature.
299 299
MACK ENGINE LINE-UP MACK ENGINE LINE-UP

MACK MP7 ENGINE LINE-UP MACK MP7 ENGINE LINE-UP
High Idle High Idle

Engine Operating Governed Peak Peak Torque Cruise Engine Operating Governed Peak Peak Torque Cruise
Model Range Power Power Torque Rise RPM Idle Model Range Power Power Torque Rise RPM Idle
MP7-355E 1200–1800 265 kW 265 kW 1844 N•m 31% 1500 ± 50 2100 MP7-355E 1200–1800 265 kW 265 kW 1844 N•m 31% 1500 ± 50 2100
Econodyne rpm (355 HP) @ (355 HP) @ (1360 lb-ft) @ Econodyne rpm (355 HP) @ (355 HP) @ (1360 lb-ft) @
1800 rpm 1500–1800 1200 rpm 1800 rpm 1500–1800 1200 rpm
rpm 500–750 rpm 500–750
MP7-405E 1200–1800 302 kW 302 kW 1980 N•m 24% 1500 ± 50 2100 MP7-405E 1200–1800 302 kW 302 kW 1980 N•m 24% 1500 ± 50 2100
Econodyne rpm (405 HP) @ (405 HP) @ (1460 lb-ft) @ Econodyne rpm (405 HP) @ (405 HP) @ (1460 lb-ft) @
1800 rpm 1800 rpm 1200 rpm 1800 rpm 1800 rpm 1200 rpm
500–750 500–750
MP7-365C 1200–1950 254 kW 272 kW 1980 N•m 60% 1500 ± 50 2100 MP7-365C 1200–1950 254 kW 272 kW 1980 N•m 60% 1500 ± 50 2100
MaxiCruise rpm (340 HP) @ (365 HP) @ (1460 lb-ft) @ MaxiCruise rpm (340 HP) @ (365 HP) @ (1460 lb-ft) @
1950 rpm 1500–1700 1200 rpm 1950 rpm 1500–1700 1200 rpm
rpm 500–750 rpm 500–750
MP7-395C 1200–1950 276 kW 295 kW 2115 N•m 56% 1500 ± 50 2100 MP7-395C 1200–1950 276 kW 295 kW 2115 N•m 56% 1500 ± 50 2100
MaxiCruise rpm (370 HP) @ (395 HP) @ (1560 lb-ft) @ MaxiCruise rpm (370 HP) @ (395 HP) @ (1560 lb-ft) @
1950 rpm 1500–1700 1200 rpm 1950 rpm 1500–1700 1200 rpm
rpm 500–750 rpm 500–750
MP7-365M 1200–2100 250 kW 272 kW 1817 N•m 60% 1500 ± 50 2170 MP7-365M 1200–2100 250 kW 272 kW 1817 N•m 60% 1500 ± 50 2170
Maxidyne rpm (335 HP) @ (365 HP) @ (1340 lb-ft) @ Maxidyne rpm (335 HP) @ (365 HP) @ (1340 lb-ft) @
2100 rpm 1500–1900 1200 rpm 2100 rpm 1500–1900 1200 rpm
rpm 500–750 rpm 500–750
MP7-405M 1200–2100 276 kW 302 kW 2007 N•m 60% 1500 ± 50 2170 MP7-405M 1200–2100 276 kW 302 kW 2007 N•m 60% 1500 ± 50 2170
Maxidyne rpm (370 HP) @ (405 HP) @ (1480 lb-ft) @ Maxidyne rpm (370 HP) @ (405 HP) @ (1480 lb-ft) @
2100 rpm 1500–1900 1200 rpm 2100 rpm 1500–1900 1200 rpm
rpm 500–750 rpm 500–750
MACK MP7 Engine Specifications MACK MP7 Engine Specifications

Bore and Stroke: 123 mm x 152 mm (4.84″ x 5.98″) Bore and Stroke: 123 mm x 152 mm (4.84″ x 5.98″)
Firing Order: 1-5-3-6-2-4 Firing Order: 1-5-3-6-2-4
Displacement: 11 liters (671 cu. in.) Displacement: 11 liters (671 cu. in.)
Thermostat: 82.2°C (180°F) Thermostat: 82.2°C (180°F)
Radiator Cap: 16-lb pressure cap Radiator Cap: 16-lb pressure cap
Oil Change Capacity: 30 liters (31.7 qts.) in engine, 6 liters (6.3 qts.) to Oil Change Capacity: 30 liters (31.7 qts.) in engine, 6 liters (6.3 qts.) to
prefill filters prefill filters
300 300
MACK MP8 ENGINE LINE-UP MACK MP8 ENGINE LINE-UP
High Idle High Idle

Engine Operating Rated Peak Peak Torque Cruise Engine Operating Rated Peak Peak Torque Cruise
Model Range Power Power Torque Rise RPM Idle Model Range Power Power Torque Rise RPM Idle
MP8-425E 1200– 317 kW 317 kW 2115 N•m 26% 1550 ± 50 2150 MP8-425E 1200– 317 kW 317 kW 2115 N•m 26% 1550 ± 50 2150
Econodyne 1800 rpm (425 HP) @ (425 HP) @ (1560 lb-ft) @ Econodyne 1800 rpm (425 HP) @ (425 HP) @ (1560 lb-ft) @
1800 rpm 1500– 1200 rpm 1800 rpm 1500– 1200 rpm
1800 rpm 650 1800 rpm 650
1800 rpm 1500– 1200 rpm 1800 rpm 1500– 1200 rpm
1800 rpm 650 1800 rpm 650
1800 rpm 1500– 1200 rpm 1800 rpm 1500– 1200 rpm
800 rpm 650 800 rpm 650
MP8-415C 1200– 291 kW 309 kW 2251 N•m 58% 1550 ± 50 2150 MP8-415C 1200– 291 kW 309 kW 2251 N•m 58% 1550 ± 50 2150
MaxiCruise 1950 rpm (390 HP) @ (415 HP) @ (1660 lb-ft) @ MaxiCruise 1950 rpm (390 HP) @ (415 HP) @ (1660 lb-ft) @
1950 rpm 1500– 1200 rpm 1950 rpm 1500– 1200 rpm
1700 rpm 650 1700 rpm 650
1950 rpm 1500– 1200 rpm 1950 rpm 1500– 1200 rpm
1700 rpm 650 1700 rpm 650
1950 rpm 1500– 1200 rpm 1950 rpm 1500– 1200 rpm
1700 rpm 650 1700 rpm 650
MP8-425M 1200– 246 kW 317 kW 2088 N•m 58% 1550 ± 50 2150 MP8-425M 1200– 246 kW 317 kW 2088 N•m 58% 1550 ± 50 2150
Maxidyne 2100 rpm (330 HP) @ (425 HP) @ (1540 lb-ft) @ Maxidyne 2100 rpm (330 HP) @ (425 HP) @ (1540 lb-ft) @
2100 rpm 1500– 1200 rpm 2100 rpm 1500– 1200 rpm
1900 rpm 650 1900 rpm 650
2100 rpm 1500– 1200 rpm 2100 rpm 1500– 1200 rpm
1900 rpm 650 1900 rpm 650
2100 rpm 1500– 1200 rpm 2100 rpm 1500– 1200 rpm
1900 rpm 650 1900 rpm 650
301 301
MACK MP8 Engine Specifications MACK MP8 Engine Specifications

Bore and Stroke: 131 x 158 mm (5.16″ x 6.22″) Bore and Stroke: 131 x 158 mm (5.16″ x 6.22″)
Firing Order: 1-5-3-6-2-4 Firing Order: 1-5-3-6-2-4
Displacement: 13 liters (793 cu. in.) Displacement: 13 liters (793 cu. in.)
Thermostat: 82.2°C (180°F) Thermostat: 82.2°C (180°F)
Radiator Cap: 16-lb pressure cap Radiator Cap: 16-lb pressure cap
Oil change capacity: Oil change capacity:

앫 Plastic Oil Pan (highway models only) — 27 liters (28.5 quarts) in 앫 Plastic Oil Pan (highway models only) — 27 liters (28.5 quarts) in
engine, 6 liters (6.3 quarts) to prefill oil filters engine, 6 liters (6.3 quarts) to prefill oil filters
앫 Steel Oil Pan (axle back vocational vehicles with front sump) — 앫 Steel Oil Pan (axle back vocational vehicles with front sump) —
31 liters (32.8 quarts) in engine, 6 liters (6.3 quarts) to prefill oil 31 liters (32.8 quarts) in engine, 6 liters (6.3 quarts) to prefill oil
filters filters
앫 Steel Oil Pan (axle forward vocational vehicles with rear sump) — 앫 Steel Oil Pan (axle forward vocational vehicles with rear sump) —
27 liters (28.5 quarts) in engine, 6 liters (6.3 quarts) to prefill oil 27 liters (28.5 quarts) in engine, 6 liters (6.3 quarts) to prefill oil
filters filters
302 302
Engine Information Plate Engine Information Plate

In compliance with emissions standards requirements, an engine In compliance with emissions standards requirements, an engine
information plate is affixed to all MACK diesel engines. This plate gives information plate is affixed to all MACK diesel engines. This plate gives
basic engine identification information (engine model, serial number basic engine identification information (engine model, serial number
and part number), advertised horsepower at rated speed, emissions and part number), advertised horsepower at rated speed, emissions
regulations to which the engine conforms and inlet and exhaust valve regulations to which the engine conforms and inlet and exhaust valve
lash settings. The engine ID plate is located on the top of the cylinder lash settings. The engine ID plate is located on the top of the cylinder
head cover. head cover.
104 104
*!*!') *!*!')
"%$&(#(###$&"($# '$)%%' "%$&(#(###$&"($# '$)%%'
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##"$!"% '&!#$ %%"#()!)()&
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,)'(& 88 ,)'(& 88
'%!"#(*&('%&%" )!&(*&('% !'% ##& &#')&%%"#( '%!"#(*&('%&%" )!&(*&('% !'% ##& &#')&%%"#(
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,)'("''$#$#(&$!'-'(" ,)'("''$#$#(&$!'-'("
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)!(&!$+')!)&'!)!$#!-
)!(&!$+')!)&'!)!$#!-

/
/
Figure 104 — Engine Information Plate Figure 104 — Engine Information Plate
303 303
CONVERSION CHART CONVERSION CHART

25.4 millimeters = 1 inch 25.4 millimeters = 1 inch
1.61 kilometers = 1 mile 1.61 kilometers = 1 mile
.473 liter = 1 pint (U.S. liquid) .473 liter = 1 pint (U.S. liquid)
.946 liter = 1 quart (U.S. liquid) .946 liter = 1 quart (U.S. liquid)
.83267 Imperial gallon = 1 gallon (U.S. liquid) .83267 Imperial gallon = 1 gallon (U.S. liquid)
.01639 liter = 1 cubic inch .01639 liter = 1 cubic inch
1.3558 Newton meters = 1 pound-foot 1.3558 Newton meters = 1 pound-foot
.746 kilowatt = 1 horsepower .746 kilowatt = 1 horsepower
6.895 kilopascals = 1 pound/square inch 6.895 kilopascals = 1 pound/square inch
(1.8 x degrees Celsius) + 32 = degrees Fahrenheit (1.8 x degrees Celsius) + 32 = degrees Fahrenheit
.03937 inches = 1 millimeter .03937 inches = 1 millimeter
.6214 miles = 1 kilometer .6214 miles = 1 kilometer
2.1134 pints (U.S. liquid) = 1 liter 2.1134 pints (U.S. liquid) = 1 liter
1.0567 quarts (U.S. liquid) = 1 liter 1.0567 quarts (U.S. liquid) = 1 liter
1.2009 gallons (U.S. liquid) = 1 Imperial gallon 1.2009 gallons (U.S. liquid) = 1 Imperial gallon
61.024 cubic inches (U.S. liquid) = 1 liter 61.024 cubic inches (U.S. liquid) = 1 liter
.7376 pound-foot = 1 Newton meter .7376 pound-foot = 1 Newton meter
1.34 horsepower = 1 kilowatt 1.34 horsepower = 1 kilowatt
.145 pound/square inch = 1 kilopascal .145 pound/square inch = 1 kilopascal
.556 x (degrees Fahrenheit −32) = degrees Celsius .556 x (degrees Fahrenheit −32) = degrees Celsius
304 304
INDEX INDEX
A A
Adjust Clutch Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Adjust Clutch Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Aftertreatment Hydrocarbon Injector . . . . . . . . . . . . . . . . . . . . . . . 119 Aftertreatment Hydrocarbon Injector . . . . . . . . . . . . . . . . . . . . . . . 119
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Air Conditioner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Air Conditioner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Air Suspension Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Air Suspension Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Allison Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Allison Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Antifreeze Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 Antifreeze Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Ash Cleaning Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Ash Cleaning Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
At the end of first 5000 km (3000 miles) or before 6500 km At the end of first 5000 km (3000 miles) or before 6500 km
(4000 miles) or 3 to 4 months (whichever comes first) . . . . . . . . 7 (4000 miles) or 3 to 4 months (whichever comes first) . . . . . . . . 7
At the first A inspection interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 At the first A inspection interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic Belt Tensioner Maintenance . . . . . . . . . . . . . . . . . . . . . . 87 Automatic Belt Tensioner Maintenance . . . . . . . . . . . . . . . . . . . . . . 87
Auxiliary Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Auxiliary Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 208 Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 208
B B
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Battery Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Battery Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Battery Warmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Battery Warmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
BioDiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 BioDiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Brake Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Brake Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
C C
Cab Mount Maintenance — LEU and MRU Models . . . . . . . . . . . . 240 Cab Mount Maintenance — LEU and MRU Models . . . . . . . . . . . . 240
Cab Mounting Maintenance and Alignment Adjustment — Cab Mounting Maintenance and Alignment Adjustment —
LEU and MRU Model Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 240 LEU and MRU Model Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 240
Cam Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Cam Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Carrier Capscrew Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Carrier Capscrew Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Carrier Housing Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Carrier Housing Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Chain Clearance Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Chain Clearance Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Chassis Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Chassis Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Clutch Assist Cylinder Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Clutch Assist Cylinder Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 148 Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 148
305 305
INDEX INDEX
CMCAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 CMCAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Cold Weather Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Cold Weather Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Coolant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Coolant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Coolant Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Coolant Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coolant Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Coolant Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Coolant Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Coolant Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Coolant System Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Coolant System Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Coolant Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Coolant Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Cooling System Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Cooling System Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cooling System Top-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Cooling System Top-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
D D
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DF-A (Ultra Low Sulfur Diesel Fuel Grades #1D and #2D) . . . . . . 277 DF-A (Ultra Low Sulfur Diesel Fuel Grades #1D and #2D) . . . . . . 277
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Diesel Fuel Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Diesel Fuel Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Diesel Fuel and Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . 280 Diesel Fuel and Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . 280
Diesel Particulate Filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Diesel Particulate Filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Diesel Particulate Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diesel Particulate Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diesel Particulate Filter Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diesel Particulate Filter Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diesel Particulate Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Diesel Particulate Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disc Wheels (Hub Piloted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Disc Wheels (Hub Piloted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Disc Wheels (Stud Piloted Ball Seat) . . . . . . . . . . . . . . . . . . . . . . . 217 Disc Wheels (Stud Piloted Ball Seat) . . . . . . . . . . . . . . . . . . . . . . . 217
Drive Belt Replacement Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Drive Belt Replacement Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Driveline Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Driveline Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Driver’s Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Driver’s Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Driveshaft Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Driveshaft Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Dual Circuit Brake System Function Test . . . . . . . . . . . . . . . . . . . . 232 Dual Circuit Brake System Function Test . . . . . . . . . . . . . . . . . . . . 232
During first 5000 km (3000 miles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 During first 5000 km (3000 miles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
306 306
INDEX INDEX
E E
Eaton Fuller Manual Transmissions . . . . . . . . . . . . . . . . . . . . . 292 Eaton Fuller Manual Transmissions . . . . . . . . . . . . . . . . . . . . . 292
Eaton Fuller Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Eaton Fuller Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Engine Oils for MACK Diesel Engines . . . . . . . . . . . . . . . . . . . . . . 267 Engine Oils for MACK Diesel Engines . . . . . . . . . . . . . . . . . . . . . . 267
Ether and Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Ether and Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 106
F F
Factors That Influence Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Factors That Influence Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Fan Arrangement Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 103 Fan Arrangement Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 103
Fastener Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Fastener Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fastener Sizes and Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Fastener Sizes and Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fastener Sizes, Types and Grades . . . . . . . . . . . . . . . . . . . . . . . . . 71 Fastener Sizes, Types and Grades . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Front (Steering) Axle and Single Rear Axle . . . . . . . . . . . . . . . . . . 185 Front (Steering) Axle and Single Rear Axle . . . . . . . . . . . . . . . . . . 185
Front Axle Static Shake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Front Axle Static Shake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Fuel Filters — MACK MP Engines . . . . . . . . . . . . . . . . . . . . . . . . . 124 Fuel Filters — MACK MP Engines . . . . . . . . . . . . . . . . . . . . . . . . . 124
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Fuel Warmers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Fuel Warmers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Fuel/Water Separator — MACK MP Engines . . . . . . . . . . . . . . . . 132 Fuel/Water Separator — MACK MP Engines . . . . . . . . . . . . . . . . 132
G G
Gear Oil Change Interval (Transmissions and Carriers) . . . . . . . . 144 Gear Oil Change Interval (Transmissions and Carriers) . . . . . . . . 144
Gear Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Gear Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Geared Components (Transmission and Carriers) . . . . . . . . . . . . 160 Geared Components (Transmission and Carriers) . . . . . . . . . . . . 160
Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
H H
Handling and Storing Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Handling and Storing Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Height Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Height Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Hose Clamp Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Hose Clamp Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
307 307
INDEX INDEX
I I
Contributing to Assembly Weakness . . . . . . . . . . . . . . . . . . . . . 77 Contributing to Assembly Weakness . . . . . . . . . . . . . . . . . . . . . 77
Contributing to Thread Stripping . . . . . . . . . . . . . . . . . . . . . . . . 75 Contributing to Thread Stripping . . . . . . . . . . . . . . . . . . . . . . . . 75
Incompatible Metric vs. Metric Fastener Systems . . . . . . . . . . . . . . 75 Incompatible Metric vs. Metric Fastener Systems . . . . . . . . . . . . . . 75
Initial Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Initial Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Initial Valve Lash and Unit Injector Pre-Load Check and Initial Valve Lash and Unit Injector Pre-Load Check and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Interwheel Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Interwheel Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
L L
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Long Stroke Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Long Stroke Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Long Stroke Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Long Stroke Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
M M
MACK Air Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 MACK Air Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
MACK Engine Line-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 MACK Engine Line-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
MACK Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 MACK Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
MACK MAXITORQUE ES T300 Series Transmissions . . . . . . . . 290 MACK MAXITORQUE ES T300 Series Transmissions . . . . . . . . 290
MACK MP7 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 300 MACK MP7 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 300
MACK MP8 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 302 MACK MP8 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 302
MACK Preventive Maintenance and Lubrication Program . . . . . . . . 14 MACK Preventive Maintenance and Lubrication Program . . . . . . . . 14
MACK Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 MACK Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Magnetic Strips and Oil Troughs . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Magnetic Strips and Oil Troughs . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
N N
Noise Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Noise Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Noise Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Noise Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Noise Emission Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Noise Emission Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
308 308
INDEX INDEX
O O
Oil and Filter Change — MACK MP Engines . . . . . . . . . . . . . . . . . 151 Oil and Filter Change — MACK MP Engines . . . . . . . . . . . . . . . . . 151
Oil Contamination of Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Oil Contamination of Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
P P
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Power Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Power Steering Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Power Steering Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Precautions When Installing Electrical Equipment . . . . . . . . . . . . . 140 Precautions When Installing Electrical Equipment . . . . . . . . . . . . . 140
Preventive Maintenance Inspection Instructions . . . . . . . . . . . . . . . 27 Preventive Maintenance Inspection Instructions . . . . . . . . . . . . . . . 27
Preventive Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preventive Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Primary Fuel Filter Replacement Procedures — MACK MP Primary Fuel Filter Replacement Procedures — MACK MP
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Priming the Fuel System — MACK MP Engines . . . . . . . . . . . . . . 129 Priming the Fuel System — MACK MP Engines . . . . . . . . . . . . . . 129
R R
Range Shift Valve Filter (Range Shifted Transmissions) . . . . . . . . 162 Range Shift Valve Filter (Range Shifted Transmissions) . . . . . . . . 162
Rear Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165, 296 Rear Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165, 296
Rear Drive Axle Alignment Specifications . . . . . . . . . . . . . . . . . . . 212 Rear Drive Axle Alignment Specifications . . . . . . . . . . . . . . . . . . . 212
Rear Engine Power Take-Off (REPTO) . . . . . . . . . . . . . . . . . . . . . 165 Rear Engine Power Take-Off (REPTO) . . . . . . . . . . . . . . . . . . . . . 165
Regular Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Regular Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Retorquing Hub Piloted Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Retorquing Hub Piloted Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Ride Height — MACK Al, AL II and MAXAIR™ 40/40A Air Ride Height — MACK Al, AL II and MAXAIR™ 40/40A Air
Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Ride Height — MaxLite™ 20–40 and 20–40 EZ Air Ride Height — MaxLite™ 20–40 and 20–40 EZ Air
Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
S S
Secondary Fuel Filter Replacement Procedures . . . . . . . . . . . . . . 128 Secondary Fuel Filter Replacement Procedures . . . . . . . . . . . . . . 128
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Specific Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Specific Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Specifications and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Specifications and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Spoke Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Spoke Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Spring Clip (U-Bolt) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Spring Clip (U-Bolt) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Spring Clip (U-Bolt) Torque Procedure . . . . . . . . . . . . . . . . . . . . . 186 Spring Clip (U-Bolt) Torque Procedure . . . . . . . . . . . . . . . . . . . . . 186
Steering Knuckle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Steering Knuckle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
309 309
INDEX INDEX
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Surge Tank/Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . 91 Surge Tank/Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . 91
T T
Tampering with Noise Control Systems is Prohibited . . . . . . . . . . . . 29 Tampering with Noise Control Systems is Prohibited . . . . . . . . . . . . 29
Tandem Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 Tandem Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Tire Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Tire Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Tire Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Tire Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Tire Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Tire Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Tire Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Tire Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Tire Wear and Driving Habits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Tire Wear and Driving Habits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Transmission, Auxiliary Transmission, Transfer Transmission, Auxiliary Transmission, Transfer
Case Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Case Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
V V
Valve and Unit Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 258 Valve and Unit Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 258
Vehicle Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Vehicle Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vehicle Identification Number (VIN) and Model Year Vehicle Identification Number (VIN) and Model Year
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Vendor Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Vendor Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Verify and Adjust Clutch Brake Squeeze . . . . . . . . . . . . . . . . . . . . 248 Verify and Adjust Clutch Brake Squeeze . . . . . . . . . . . . . . . . . . . . 248
Verify Clutch Release Yoke and Release Bearing Travel . . . . . . . 256 Verify Clutch Release Yoke and Release Bearing Travel . . . . . . . 256
W W
Wheel Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Wheel Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Wheel Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Wheel Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
310 310
MAINTENANCE RECORD MAINTENANCE RECORD
MAINTENANCE RECORD MAINTENANCE RECORD
SERVICE PERFORMED DATE MILEAGE SERVICED BY SERVICE PERFORMED DATE MILEAGE SERVICED BY
311 311
SERVICE LITERATURE SERVICE LITERATURE

If you would like to know more about servicing your new MACK Truck, If you would like to know more about servicing your new MACK Truck,
several options are available. We offer three different types of literature several options are available. We offer three different types of literature
which are described in Figure 105, Figure 106 and Figure 107. Decide which are described in Figure 105, Figure 106 and Figure 107. Decide
which type fits your needs and order from your local dealer or which type fits your needs and order from your local dealer or
distributor. Service literature can also be ordered online at distributor. Service literature can also be ordered online at
www.macktrucks.com. www.macktrucks.com.
105 105
Figure 105 — TS576 — Mack Components Service Manual Figure 105 — TS576 — Mack Components Service Manual
312 312
106 106
# $#"&% # $#"&%

# ""'
### # ""'
###
$#%" & " $#%" & "
! $# $ &" ! $# $ &"
$

! $#"& $

! $#"&
% !$### % !$###
%" %"%#$ %" %"%#$
!!" $ ' !!" $ '
""%#$ % ""%#$ %
# &$" ( # &$" (
#$'$$
#$'$$

#"& "$ #%!!
#"& "$ #%!!

Figure 106 — T473 — Custom Highway Truck Service Manual Figure 106 — T473 — Custom Highway Truck Service Manual
313 313
107 107

Figure 107 — Individual Component Service Manuals Figure 107 — Individual Component Service Manuals
314 314
TS49407 © Mack Trucks, Inc. 2007
JULY 2007 (SUPERSEDES JUNE 2007) Printed in U.S.A.

2007 Maintenance and Lubrication Manual

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2007 Maintenance and Lubrication Manual

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JAN

PR MAY JUN JUL AUG SEP OCT NOV DEC

OCT NOV DEC FOR

(Revised July 2007, (Revised July 2007,

Figure 1 — Mack Model Chassis Figure 1 — Mack Model Chassis

SAFETY INFORMATION SAFETY INFORMATION

MAKE SAFETY FIRST . . . MAKE SAFETY FIRST . . .

. . . AND MAKE IT LAST . . . AND MAKE IT LAST

ADVISORY LABELS ADVISORY LABELS

Figure 2 — ASE Certification Figure 2 — ASE Certification

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . i MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . i

TIRE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 228 TIRE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 228

TABLE OF CONTENTS TABLE OF CONTENTS

DIESEL PARTICULATE FILTERS . . . . . . . . . . . . . . . . . 4 DIESEL PARTICULATE FILTERS . . . . . . . . . . . . . . . . . 4

DIESEL PARTICULATE FILTERS DIESEL PARTICULATE FILTERS

Diesel Particulate Filter Maintenance Diesel Particulate Filter Maintenance

Diesel Particulate Filter Precautions Diesel Particulate Filter Precautions

VEHICLE BREAK-IN VEHICLE BREAK-IN

At the first A inspection interval At the first A inspection interval

DAILY INSPECTION DAILY INSPECTION

GENERAL APPEARANCE GENERAL APPEARANCE

Steering System Steering System

CLIMB INTO CAB CLIMB INTO CAB

Start the Engine Start the Engine

END OF THE DAY END OF THE DAY

PREVENTIVE MAINTENANCE PROGRAM PREVENTIVE MAINTENANCE PROGRAM

CHASSIS MAINTENANCE AND LUBRICATION CHASSIS MAINTENANCE AND LUBRICATION

*Whichever occurs first. *Whichever occurs first.

SEVERE VOCATIONAL VERY SEVERE SEVERE VOCATIONAL VERY SEVERE

SEVERE VOCATIONAL VERY SEVERE SEVERE VOCATIONAL VERY SEVERE

*Whichever occurs first. *Whichever occurs first.

CHASSIS MAINTENANCE AND LUBRICATION CHASSIS MAINTENANCE AND LUBRICATION

SEVERE VOCATIONAL VERY SEVERE SEVERE VOCATIONAL VERY SEVERE

*Whichever occurs first. *Whichever occurs first.

NOTES TABLE NOTES TABLE

Preventive Maintenance Inspection Instructions Preventive Maintenance Inspection Instructions

“A” is a light inspection. “A” is a light inspection.

“B” is a more detailed check. “B” is a more detailed check.

“L” is a chassis lubrication. “L” is a chassis lubrication.

NOISE EMISSION CONTROL NOISE EMISSION CONTROL

Noise Emission Control Systems Noise Emission Control Systems

ROAD TEST ROAD TEST

ENGINE: Inspection ENGINE: Inspection

Check operation of exhaust pyrometer. A, B, C, D Check operation of exhaust pyrometer. A, B, C, D

AIR COMPRESSOR: AIR COMPRESSOR:

STEERING: Inspection STEERING: Inspection

Check for pull. A, B, C, D Check for pull. A, B, C, D

Check for drag. A, B, C, D Check for drag. A, B, C, D

PARKING BRAKES: Inspection PARKING BRAKES: Inspection

Check operation: A, B, C, D Check operation: A, B, C, D

AIR CONDITIONER: AIR CONDITIONER:

Check operation. A, B, C, D Check operation. A, B, C, D

TRANSMISSION/AUX TRANS./TRANSFER CASE/FLYWHEEL PTO: TRANSMISSION/AUX TRANS./TRANSFER CASE/FLYWHEEL PTO:

CARRIER: Inspection CARRIER: Inspection

PROPELLER SHAFT: PROPELLER SHAFT:

ENGINE BRAKE: ENGINE BRAKE:

CHASSIS INSPECTION CHASSIS INSPECTION

CAB: Inspection CAB: Inspection

CAB: Inspection CAB: Inspection

Check operation of window regulators. C, D Check operation of window regulators. C, D

TILT CAB: TILT CAB:

Check anti-vibration pads on frame-mounted C, D Check anti-vibration pads on frame-mounted C, D

BATTERY: Inspection BATTERY: Inspection

STARTER: Inspection STARTER: Inspection

Whichever occurs first. Whichever occurs first.

Whichever occurs first. Whichever occurs first.

Whichever occurs first. Whichever occurs first.