MACK MP7, MP8, MP10, PI, CHU Service Manual

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BODY BUILDER INSTRUCTIONS

Mack Trucks

Body Builder; Engine, MP7, MP8, and MP10

PI / CHU, AN / CXU, GR / GU, TD

Introduction

This information provides details for the MP7, MP8, and MP10 engines for MACK vehicles.

Note: We have attempted to cover as much information as possible. However, this information does not cover all the unique variations that a vehicle chassis may present. Note that illustrations are typical but may not reflect all the variations of assembly.

All data provided is based on information that was current at time of release. However, this information is subject to change without notice .

Please note that no part of this information may be reproduced, stored, or transmitted by any means without the express written permission of MACK Trucks, Inc.

LR, TE / MRU

Section 2

Contents:

• “Fuel and Oil”, page 2

• “Engine Overview”, page 3

• “Exhaust Aftertreatment System”, page 10

• “Heated Dump Bodies ”, page 25

• “Exhaust Back Pressure for US2010 and GHG2017 Engines”, page 26

• “TE / MRU, LR Exhaust Aftertreatment System Regeneration”, page 27

• “Instrument Cluster Icons Overview”, page 29

• “In-Transit Heat Cooling System ”, page 34

• “Fittings, Fuel Line, Replacement”, page 38

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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General

Fuel and Oil

CAUTION

Diesel engines for 2006 and later model year vehicles are designed to operate only with ultra low sulfur diesel (ULSD) fuel. Use of fuel other than ULSD will reduce the efficiency and durability of the engine, permanently damage the advanced emission control systems, reduce fuel economy and possibly prevent the engine from running at all. Manufacturer's warranties are likely to be rendered void by usage of improper or incorrect fuel, and usage of fuels other than ULSD fuel in diesel-powered vehicles is illegal and punishable with civil penalties. Use of fuel additives to compensate for the lower sulfur content is NOT recommended by MACK Trucks, Inc.

Fuel sold for use in diesel-powered engines for 2006 and later model year vehicles may only contain a maximum sulfur content of 0.0015% by weight. This was done to reduce particle emissions in the exhaust.

Bio Diesel

The only biodiesel fuel approved by MACK Trucks, Inc. for use in MACK Engines is soy methyl ester (SME or SOME) in blends up to B20 concentration (20% blend).

Note: Although higher concentrations are available, concentration up to B20 (maximum) are the only blends currently approved by MACK Trucks, Inc.

Greenhouse Gas 2017

Maximum limit will be B10 concentration (10% blend).

Engine Oil

EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use in all 2017 emission compliant MACK engines. Chassis equipped with a 2017 emission compliant engine, which can be identified by the presence of an aftertreatment selective catalytic reduction (SCR) system, also require the use of Ultra Low Sulfur Diesel (ULSD) fuel. EO-O Premium Plus oils exceed the new American Petroleum Institute (API) service category CJ-4.

Notes

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Overview

DANGER

Do not use ether or other combustible starting aids in any MACK engine. Introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death.

CAUTION

DO NOT crank the engine for more than 30 seconds at a time; wait 15 minutes after each try to allow the starter to cool. Failure to follow these instructions could cause starter damage.

Note: Some starters are equipped with starter protection. If the engine is running, the starter temperature is too high, the transmission is not in neutral or the clutch pedal is not depressed, starter engagement is inhibited.

Allow the engine to slow down and idle for 3 to 5 minutes before shutting it off. This allows the turbocharger to cool down and the cooling system to dissipate the engine heat. Switch the engine off by turning the ignition key to the OFF position.

CAUTION

Shutting off an engine immediately after high speed or full load operation can damage the turbocharger and cause heat stress in the engine. Always let the engine idle for 3 to 5 minutes before shutting it off.

MACK Trucks, Inc. does not recommend the use of winterfronts, shutters or any other shield in front of the grille or radiator package under normal circumstances. Today's electronically controlled engines are designed to operate in cold temperatures without a winterfront. These devices, if not used properly, can cause higher exhaust gas temperatures, power loss, excessive fan usage, failure of the charge-air-cooler (CAC) and a reduction in fuel economy. Winterfronts can be used in the wintertime during very cold weather if used properly. In these cases, engine coolant and intake air temperatures must also be carefully monitored and controlled. Please see your authorized MACK Truck dealer for recommended winterfronts.

CAUTION

MACK is now using the ambient air temperature (AAT) sensor for on board diagnostic (OBD) monitoring. If a customer installs a winterfront or blocks the radiator opening and blocks airflow to the sensor, they will likely set an OBD diagnostic trouble code (DTC) for inaccurate sensor data due to restricted airflow across the sensor.

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Shutdown System

DANGER

Failure to take the necessary precautions when the STOP telltale is on can result in automatic engine shutdown and the loss of power steering. Vehicle crash can occur.

The engine shutdown system will automatically derate or stop the engine when one or more of the conditions listed below reaches a critical stage:

• High Engine Coolant Temperature (ECT)

• Low Engine Oil Pressure (EOP)

• Low Engine Coolant Level (ECL)

• High Crankcase Pressure (CCP)

When the shutdown is activated, the telltales come on along with display symbols and the buzzer is also activated. After a brief time, the engine shuts down. Find a safe place to pull off the road as soon as possible.

After the engine has been shut down by the system, turn the ignition key to the OFF position. If necessary, the engine can be restarted for a brief time so that the vehicle may be pulled off the road.

The alarm will remain activated until repairs have been made to correct the problem that caused the shutdown.

CAUTION

Continuously restarting the engine once the shutdown system is active may result in severe engine damage.

Refer to the driver information display (DID) manual for information about the display symbols.

W2116208

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Overview, MP7 and MP8 Left Side View

W2006034

MP8 Engine Shown, MP7 Engine Similar

1. Breather Tube 9. Fuel Filter

2. Intake Manifold 10. Hand-Priming Pump

3. Air Compressor 11. Crankcase Ventilator

4. Power Steering Pump 12. Alternator

5. Fuel Pump 13. AC Compressor

6. Engine Control Module (ECM) 14. Alternator/AC Compressor Belt

7. Fuel Filter 15. Fan/Coolant Pump Belt

8. Fuel/Water Separator 16. Exhaust Gas Recirculation (EGR) Mixing Chamber

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Overview, MP7 and MP8 Right Side View

MP8 Engine Shown, MP7 Engine Similar

17. Exhaust Manifold 24. Venturi Pipe

18. Valve Cover 25. Oil Filters

19. Intake Air Heater (IAH) optional 26. Oil Pan

20. Thermostat 27. Exhaust Gas Recirculation (EGR) Cooler

21. Belt Tensioner 28. Turbocharger

22. Coolant Pump 29. Starter Motor

23. Coolant Filter 30. Exhaust Gas Recirculation (EGR) Valve

W2006035

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Overview, MP10 Left Side View

W2006037

1. Breather Tube 10. Fuel Filter

2. Intake Manifold 11. Hand-Priming Pump

3. Air Compressor 12. Alternator

4. Power Steering Pump 13. AC Compressor

5. Fuel Pump 14. Alternator/AC Compressor Belt

6. Crankcase Ventilator 15. Fan/Coolant Pump Belt

7. Engine Control Module (ECM) 16. Venturi Pipe

8. Fuel Filter 17. Exhaust Gas Recirculation (EGR) Mixing Chamber

9. Fuel/Water Separator

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Overview, MP10 Right Side View

W2006036

18. Exhaust Manifold 25. Oil Filters

19. Valve Cover 26. Exhaust Gas Recirculation (EGR) Cooler

20. Intake Air Heater (IAH) 27. Oil Pan

21. Thermostat 28. Starter Motor

22. Belt Tensioner 29. Turbocharger

23. Coolant Pump 30. Exhaust Gas Recirculation (EGR) Valve

24. Coolant Filter

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Engine Clearance

A minimum of 40.64 mm (1.6 in) of clearance should be maintained around the engine. Additionally, no equipment should be installed that would restrict air flow through the radiator or to the engine air intake.

W2031928

Fig. 1 Allow Sufficient Clearance Around Engine

A. 40.64 MM (1.6 in) Minimum

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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MACK, Emissions Solution

Exhaust Aftertreatment System

Your new MACK chassis is equipped with emission compliant engine, with an engine exhaust aftertreatment system (DPF) and selective catalytic reduction (SCR) system. Vehicles equipped with a DPF require the use of EO-O Premium Plus (or VDS-4) specification high performance diesel engine oil and ultra low sulfur diesel (ULSD) fuel.

CAUTION

Use of diesel fuel other than ULSD and engine oils other than EO-O Premium Plus (or VDS-4), will adversely affect performance, efficiency and durability of the DPF system and the engine, to the point where the engine may not run at all. Manufacturer's warranties will also be rendered void due to usage of improper fuel. Unapproved fuel additives (including engine oil) are NOT permitted.

MACK Trucks, Inc. offers two different types of DPF systems:

• Conventional DPF (passive regeneration and parked regeneration)

• Spark Assisted DPF (moving regeneration and parked regeneration)

as well as two different mounting styles:

1. MACK vertical back-of-cab DPF (both conventional DPF and spark assisted DPF)

2. MACK-Cap DPF, which is a space saving unit that is mounted inside the frame (conventional only)

C0029353

A DPF takes the place of the standard muffler. The DPF is used to meet EPA requirements to help reduce soot and particulate emissions into the atmosphere. The particulates are removed by collecting in the DPF unit, where they are eventually oxidized during passive or active regeneration. The electrical system and exhaust aftertreatment system of the vehicle will determine when regeneration is required. MACK Trucks, Inc., uses two exhaust aftertreatment systems: conventional and spark assisted.

Conventional exhaust aftertreatment systems use aftertreatment DPF passive-active regeneration. The passive regeneration process oxidizes the particulates captured in the DPF while the vehicle is in operation. A diesel oxidation catalyst (DOC) raises the exhaust gas temperature (EGT) to approximately 260°C (500°F), the temperature at which a chemical reaction takes place to oxidize the soot (passive regeneration).

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

USA141023213 Date 2.2018 Body Builder; Engine, MP7, MP8, and MP10 Page 10 (40)

Aftertreatment DPF spark assisted systems use active regeneration. Regeneration takes place after a certain number of engine operating hours and begins when an air/fuel mixture is injected into the thermal regenerator and raises the temperature inside the unit to the point where the soot oxidation takes place.

Conventional exhaust aftertreatment systems are used in highway and certain vocational applications. Spark assisted exhaust aftertreatment systems are used mainly in refuse collection applications.

Depending on how the vehicle is set up, aftertreatment DPF regeneration can occur while the vehicle is being driven (referred to as a "moving" regeneration) or when the vehicle is parked and idling (referred to as a "parked" regeneration).

CAUTION

When aftertreatment DPF active regeneration occurs (with either system), the temperature of the exhaust will be elevated. DO NOT park the vehicle with the exhaust outlet under low hanging overhead flammable objects such as trees, awnings, etc., that could be damaged by elevated exhaust gas temperatures (EGTs). DO NOT remove the diffuser.

CAUTION

If the vehicle is in a location that may be hazardous when an aftertreatment DPF active regeneration begins (i.e., in close proximity to flammable materials or gases), the regeneration should be stopped by pushing the DPF switch to the "Stop Regeneration" position. If an active regeneration is stopped by the vehicle operator, it should be initiated at a later time when the vehicle is in a safe location. However, if an active regeneration is stopped repeatedly, the vehicle may need to be taken to a MACK service facility. The service facility will use a service tool to manually initiate the regeneration.

WARNING

For chassis equipped with a heated dump body, be aware that temperature around the area where the exhaust enters the body, as well as the product contained in the body, may be elevated, particularly during aftertreatment DPF regeneration.

Extended Idling and Aftertreatment System Conditioning

Extended idling performed on this vehicle equipped with an exhaust aftertreatment system should be carried out at a low engine idle speed. There is no benefit to using a raised engine idle speed for extended idling. The only exception is for active power takeoff (PTO) . Utilizing an engine speed above 1,300 rpm is recommended for vehicles which perform extended idling with an active PTO.

During periods of extended idling, normally greater than 8 hours, the conventional aftertreatment diesel particulate filter (DPF) system needs to perform a routine conditioning cycle. The conditioning cycle is controlled by the engine control module (ECM) and will start and stop automatically as needed. The DPF conditioning is required to maintain normal exhaust aftertreatment system function and should not be stopped. DPF conditioning will not occur on aftertreatment DPF spark assisted systems.

During these events the engine speed (RPM) will increase to approximately 1,050 - 1,400 rpm, for non-PTO , in order to complete the exhaust aftertreatment conditioning cycle. Exhaust gas temperatures (EGT) will also elevate slightly but remain much lower than that reached during aftertreatment DPF regeneration and present no danger.

If a compatible driver display is available a message will be displayed when the conditioning cycle is in progress. The message indicated in the driver's display will be "ATS Conditioning in Progress, No Action Required." If no driver display is available there will be no indication of an DPF conditioning event except for the automatic increase in RPM.

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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Exhaust Aftertreatment System (EAS)

PI / CHU, AN / CXU, GR / GU, TD Standard System View

W2029933

1. Selective Catalytic Reduction (SCR) Catalyst

2. Aftertreatment Diesel Exhaust Fluid (DEF) Dosing Valve

DEF is a reactant that's key to the SCR process. It's a nontoxic, ultra-pure solution of urea and ultra-pure water. Urea is a compound of nitrogen that turns to ammonia when heated. It is used in a variety of industries, perhaps most commonly as a fertilizer in agriculture. The fluid is non flammable, and is not dangerous when handled as recommended. However, it is highly corrosive to certain metals, especially copper and brass. Read the separate section concerning the handling of DEF solution.

3. Aftertreatment Diesel Particulate Filter (DPF)

4. Aftertreatment DEF Tank

GHG17 ClearTech One

One box EATS.

W2116209

Mack Body Builder Instructions PI / CHU, AN / CXU, GR / GU, TD, LR, TE / MRU

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